An integrated approach to design for manufacturing and assembly based on reduction of product development time and cost

Selvaraj, P.; Radhakrishnan, P.; Adithan, M.

doi:10.1007/s00170-008-1580-8

Cited by 85 publications

(34 citation statements)

References 6 publications

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“…Thus in WLA, the process inspectors has set standards initially itself to match the designer's requirement with the technicians having set the capabilities of the facilities accordingly. This is an activity pattern at every process [16]. By this the inspector's clarification time on every parameter in the process is reduced considerably with the tasks and expected outcome being in total consensus with the intents of the designer, manufacturer and inspector in every process.…”

Section: Common Stage Wla Modelmentioning

confidence: 94%

Prototype Aircraft Sub-Assembly Fabrication using Common Stage Walking Line Assembly Model

Gopinath

Ravishankar

2015

Int. J. Vehicle Structures and Systems

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This paper describes the application of Walking Line Assembly (WLA) in prototype fabrication of yoke sub-assembly and its effectiveness. The technical aspects and challenges involved in development and fabrication of engine mount yoke tube assembly for a civil aircraft are presented. Activities representing reverse engineering process and fabrication of yoke tube are detailed comprehensively. WLA model adopted for this assembly is compared with conventional methods and fixed layouts. Further, WLA model is modified with a common stage set on every process where the expected capability of the task in the shop floor is brought out in consensus with the operational demand and standards. This is achieved with very little disturbance to the existing aircraft fixed line fabrication set up. This model has given encouraging results by expediting the processes and provides an ideal option for building of prototypes in the development stage of an aircraft project.

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Section: Common Stage Wla Modelmentioning

confidence: 94%

Prototype Aircraft Sub-Assembly Fabrication using Common Stage Walking Line Assembly Model

Gopinath

Ravishankar

2015

Int. J. Vehicle Structures and Systems

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“…[2] Such heavy weight steel housing structures with integrated dynamic seals require high energy, additional machining and assembly steps in the manufacturing process, which adds up to high production time and costs. [3] Through the use of a sophisticated lightweight multi-material structure (aluminum alloys, high strength steel, and thermoplastic polymers) and fragmenting an existing steel housing into its sub-functions (load bearing, housing, and sealing) it is feasible to create a hybrid pump housing structure, where the actual housing function can be realized by an injection molded polymeric housing. [4,5] A polymeric housing structure enables the simple implementation of static and dynamic seals as well as several kinds of inserts by injection molding.…”

Section: Introductionmentioning

confidence: 99%

Process Influences on the Materials Interface of an Injection Molded Hard‐Soft‐Component

Frick

Spadaro

2018

Macromolecular Symposia

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Combining a soft thermoplastic elastomer with a hard polymeric material by multi‐component injection molding provides a novel and sophisticated alternative for mounting a vulcanized dynamic elastomeric seal part into a rigid housing. Such assembly injection molding is new and challenging, but promises several economic advantages. The main issue within such a development is the assurance of sufficient bond strength between soft and hard component, in order to withstand the service load conditions safely. This paper studies certain process influences on the interface condition between the materials. The strength of the adhesive bond of composite test specimens consisting of a hard outer ring and a soft inner ring with integrated rotary seal lip are evaluated. The injection molded and investigated composite parts consist of glass fiber reinforced polybutylene terephthalate (PBT‐GF30) as hard component and a thermoplastic polyurethane (TPU) as soft component. The required force to reach delamination between hard and soft component is monitored and correlated with the surface structure and properties of differently plasma pre‐treated hard components. Supposed a material combination and the contact temperature are defined the surface conditions of the hard component play the major role with respect to the adhesion bond strength.

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“…In DFM, it is important to consider the performance of products together with their manufacturing costs and manufacturability. However, conventional DFM typically focuses on a simple method for evaluating manufacturing costs [2,5,6] via, for example, simplification and standardization of design and manufacturing processes [7], although the lowering of performances due to such simplification has recently been considered in some research [8,9]. Research on DFM methods for improving product designs while ensuring their performance is relatively scarce, and reliance on design engineers' expertise to achieve product design improvements that also maintain or improve performance is still the norm.…”

Section: Introductionmentioning

confidence: 99%

Manufacturability evaluation for molded parts using fictitious physical models, and its application in topology optimization

Sato

Yamada

Izui

et al. 2017

Int J Adv Manuf Technol

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Manufacturing methods using molds, such as casting and injection molding, are widely used in industries. A basic requirement when using such manufacturing methods is that design engineers must design products so that they incorporate certain geometrical features that allow the mold parts to be removed from the created solid object. In the present study, we propose a manufacturability evaluation method especially adapted for the use of molds. To evaluate the manufacturability, we introduce fictitious physical models that are described by steady-state anisotropic advectiondiffusion equations. In these fictitious physical models, material domains have a virtual source term and the advection directions are aligned with the directions along which the mold parts are parted. Void regions, where the values of all fictitious physical fields are high, then represent either undercut geometries that would prevent the mold from being released, or interior voids that cannot be cast. Consequently, manufacturability can be evaluated using these fictitious physical fields. Furthermore, in the present study, we integrate this evaluation method with topology optimization and propose a scheme for imposing a molding constraint within the topology optimization procedure. This newly proposed topology optimization method can consider the position of mold parting lines prior to the detailed optimization procedure. Several numerical examples are provided to demonstrate the validity and effectiveness of the proposed method.

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An integrated approach to design for manufacturing and assembly based on reduction of product development time and cost

Cited by 85 publications

References 6 publications

Prototype Aircraft Sub-Assembly Fabrication using Common Stage Walking Line Assembly Model

Prototype Aircraft Sub-Assembly Fabrication using Common Stage Walking Line Assembly Model

Process Influences on the Materials Interface of an Injection Molded Hard‐Soft‐Component

Manufacturability evaluation for molded parts using fictitious physical models, and its application in topology optimization

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