Operations Research, Systems Engineering and Industrial Engineering Commons^™

Worn Tool Forces Based On Ploughing Stresses, Daniel Waldorf, Shiv G. Kapoor, Richard E. Devor

Industrial and Manufacturing Engineering

Recent work in modeling of the ploughing mechanism in basic metal machining may provide a means of estimating the additional forces to be expected when cutting with a worn tool. The results predict the rubbing stresses due to the finite radius of an unworn tool edge. Since an unworn tool can be thought of as a worn tool with a wear land width VB = 0, these stresses can make up part of a strategy for predicting the additional forces incurred by a worn tool. This paper develops a wear model by proposing a technique for utilizing the stresses predicted …

Screen Printing Process Design Of Experiments For Fine Line Printing Of Thick Film Ceramic Substrates, Jianbiao Pan, Gregory L. Tonkay, Alejandro Quintero

Industrial and Manufacturing Engineering

Screen printing has been the dominant method of thick film deposition because of its low cost. Many experiments in industry have been done and many models of the printing process have been developed since the 1960’s. With a growing need for denser packaging and a drive for higher pin count, screen printing has been refined to yield high resolution prints. However, fine line printing is still considered by industry to be difficult. In order to yield high resolution prints with high first pass yields and manufacturing throughput, the printing process must be controlled stringently.

This paper focuses on investigating the …

A Slip-Line Field For Ploughing During Orthogonal Cutting, Daniel J. Waldorf, Richard E. Devor, Shiv. G. Kapoor

Industrial and Manufacturing Engineering

Under normal machining conditions, the cutting forces are primarily due to the bulk shearing of the workpiece material in a narrow zone called the shear zone. However, under finishing conditions, when the uncut chip thickness is of the order of the cutting edge radius, a ploughing component of the forces becomes significant as compared to the shear forces. Predicting forces under these conditions requires an estimate of ploughing. A slip-line field is developed to model the ploughing components of the cutting force. The field is based on other slip-line fields developed for a rigid wedge sliding on a half-space and …

Fuzzy Logic Control Of A Model Airplane, Jon C. Ervin, Sema E. Alptekin

Industrial and Manufacturing Engineering

Common uses of fuzzy logic control today are found in relatively simple applications in products. These applications only scratch the surface of the potential of fuzzy logic control in complex mechatronic systems. In order to demonstrate the utility of fuzzy logic in complex device control, a fuzzy logic fly-by-wire system has been developed for a model airplane. The model airplane is a complex system of several critical inputs that require rapid processing and action in order to maintain flight stability. In addition, payload and power constraints severely limit the size, weight and processing power of the hardware to be carried …

Development Of A Mechatronics Design Studio, Sema E. Alptekin

Industrial and Manufacturing Engineering

Mechatronics is a combination of mechanics, electronics and information technology intended to raise the intelligence level and flexibility of products and devices. There is a need to develop programs and laboratories in Mechatronics to create an understanding of how new technologies influence the traditional methods of designing products and manufacturing systems. A model "Mechatronics Design Studio" has recently been developed to support the Mechatronics and Manufacturing Automation courses offered at Cal Poly's Industrial and Manufacturing Engineering Department. Laboratory experiments have been developed and several student projects have been completed. In this paper, an overview of the design studio and select …

Preparing The Leaders For Mechatronics Education, Sema E. Alptekin

Industrial and Manufacturing Engineering

Mechatronics is the synergetic combination of precision mechanical engineering, electronic control and systems thinking in the design of products and processes. There is a need to develop interdisciplinary programs in Mechatronics that better prepare our graduates to design, build, and operate the products and systems of today and tomorrow. To address this need, National Science Foundation funded a project entitled "Preparing the Leaders for Mechatronics Education" undertaken by Cal Poly in 1995 - 1996. In this paper, the activities that took place during this two-year program is outlined. Several courses and course modules have already been developed and implemented by …

A Psychological Perspective On Service Segmentation Models: The Significance Of Accounting For Consumers' Perceptions Of Waiting And Service, Ziv Carmon, J. George Shanthikumar, Tali F. Carmon

Industrial and Manufacturing Engineering

We examine how service should be divided and scheduled when it can be provided in multiple separate segments. We analyze variants of this problem using a model with a conventional function describing the waiting cost, that is modified to account for some aspects of the psychological cost of waiting in line. We show that consideration of the psychological cost can result in prescriptions that are inconsistent with the common wisdom of queuing theorists derived according to the conventional approach (e.g., equal load assignments). More generally, our intention in this paper is to illustrate that aspects of the psychological cost of …

A Preliminary Model For Lot Sizing In Semiconductor Manufacturing, Tali F. Carmon, Steven Nahmias

Industrial and Manufacturing Engineering

No abstract provided.

Error Recovery In Intelligent Robotic Workcells, R. D. Borchelt, Sema E. Alptekin

Industrial and Manufacturing Engineering

This paper focuses on the requirements for achieving automated diagnosis and error recovery in a robotic assembly cell. Untended robust operation is the goal which is discussed, and the use of a knowledge-base oriented diagnostic/control system to support on-line error recovery is advocated. It is proposed that error recovery attempts should be made, not only based on information gathered by system sensors, but also by using additional cell-specific knowledge pertaining to recovery strategies. Recovery attempts are to be made even in the absence of complete diagnosis, in order to gather additional information. A control structure developed to implement this approach …

The Importance Of Considering Size Effect Along The Cutting Edge In Predicting The Effective Lead Angle For Turning, William J. Endres, Daniel Waldorf

Industrial and Manufacturing Engineering

The concept of an effective orthogonal cutting edge in turning is considered. The orientation of this edge in the radial-longitudinal plane, as commonly modeled through an effective lead angle, is studied. The methods of effective lead angle prediction used in numerous previously developed force models are plagued with large errors over ranges of process inputs, in particular feed rate and depth of cut. Four previously developed methods of effective lead angle prediction are reviewed and compared to a new method presented here. This new method accounts for the size effect as introduced through the variation in chip thickness along the …

Set-Up Saving Schemes For Printed Circuit Boards Assembly, Oded Z. Maimon, Ezey M. Dar-El, Tali F. Carmon

Industrial and Manufacturing Engineering

Focusing on a basic printed circuit board (PCB) assembly line configuration characterized by very long set-up times, we examine two scheduling methods that can significantly reduce the set-up. Both methods -the Grouped Set-Up (GSU) method that has been recently introduced in the literature and the Sequence Dependent Scheduling (SDS) method, which has not been studied in this context -are based on component commonality among PCB types. Using the typical traditional scheduling method as a benchmark, the GSU and the SDS methods are compared in terms of three performance measures: line throughput, average work-in-process (WIP) inventory level, and implementation complexity. Guidelines …

Integration Of Simulation Modeling And Computer Aided Production Management In Computer Integrated Enterprise, Emine Persentili, Sema E. Alptekin

Industrial and Manufacturing Engineering

Designing efficient and integrated manufacturing systems is the first step in attaining computer integrated enterprises (CIE). Integration of planning and implementation phases of manufacturing is essential for taking full advantage of the CIE. In order to design reliable and efficient manufacturing systems, the designers must consider the impacts of planning decisions made by computer aided production management (CAPM) modules on implementations held in manufacturing cells. This paper focuses on two issues. The first issue is importance and necessity of integrating CAPM modules with manufacturing cells. The second issue includes major features of the object-oriented approach and their relevance to our …

Artificial Neural Networks For Robotics Coordinate Transformation, Stephen Aylor, Luis Rabelo, Sema E. Alptekin

Industrial and Manufacturing Engineering

Artificial neural networks with such characteristics as learning, graceful degradation, and speed inherent to parallel distributed architectures might provide a flexible and cost solution to the real time control of robotics systems. In this investigation artificial neural networks are presented for the coordinate transformation mapping of a two-axis robot modeled with Fischertechnik physical modeling components. The results indicate that artificial neural systems could be utilized for practical situations and that extended research in these neural structures could provide adaptive architectures for dynamic robotics control.

Automatic Recognition Of Tool Wear On A Face Mill Using A Mechanistic Modeling Approach, Daniel Waldorf, Shiv G. Kapoor, Richard E. Devor

Industrial and Manufacturing Engineering

A strategy is developed for identifying cutting tool wear on a face mill by automatically recognizing wear patterns in the cutting force signal. The strategy uses a mechanistic model development to predict forces on a lathe under conditions of wear and extends that model to account for the multiple inserts of a face mill. The extended wear model is then verified through experimentation over the life of the inserts. The predicted force signals are employed to train linear discriminant functions to identify the wear state of the process in a manner suitable for on-line application.

On Capacity Modeling For Production Planning With Alternative Machine Types, Robert C. Leachman, Tali F. Carmon

Industrial and Manufacturing Engineering

Analyzing the capacity of production facilities in which manufacturing operations may be performed by alternative machine types presents a seemingly complicated task. In typical enterprise-level production planning models, capacity limitations of alternative machine types are approximated in terms of some single artificial capacitated resource. In this paper we propose procedures for generating compact models that accurately characterize capacity limitations of alternative machine types. Assuming that processing times among alternative machine types are identical or proportional across operations they can perform, capacity limitations of the alternative machine types can be precisely expressed using a formulation that is typically not much larger …

Tardiness Heuristic For Scheduling Flexible Manufacturing Systems, Ali S. Kiran, Sema E. Alptekin, A. Celal Kaplan

Industrial and Manufacturing Engineering

This paper evaluates the tardiness performance of a sampling-based adaptive heuristic in a dynamic manufacturing environment. A test bed, following a real world manufacturing system, has been developed. The proposed algorithm has been implemented in this simulated environment. After fine tuning the algorithm, it has been tested in various shop conditions. The results of these simulation studies are summarized.

Synergy Of Artificial Neural Networks And Knowledge-Based Expert Systems For Intelligent Fms Scheduling, Luis Carlos Rabelo, Sema E. Alptekin, Ali S. Kiran

Industrial and Manufacturing Engineering

In this paper we describe a hybrid architecture that integrates artificial neural networks and knowledge-based expert systems to generate solutions for the real time scheduling of flexible manufacturing systems. The artificial neural networks perform pattern recognition and, due to their inherent characteristics, support the implementation of automated knowledge acquisition and refinement schemes through a feedback mechanism. The artificial neural network structures enable the system to recognize patterns in the tasks to be solved in order to select the best scheduling rule according to different demands. The knowledge-based expert systems are the higher order elements which drive the inference strategy and …

A Suggested Model Program For Cim Education, Sema E. Alptekin

Industrial and Manufacturing Engineering

No abstract provided.

Adaptive Scheduling And Control Using Artificial Neural Networks And Expert Systems For A Hierarchical/Distributed Fms Architecture, Luis Carlos Rabelo, Sema E. Alptekin

Industrial and Manufacturing Engineering

An adaptive expert scheduler was developed that learns by itself and adapts to the dynamic FMS environment. This hybrid system uses a symbiotic architecture composed of expert systems (ESs) and artificial neural networks (ANNs) and provides a learning scheme guided by past experience. The artificial neural networks recognize patterns in the tasks to be solved in order to select the best scheduling rule according to different criteria. The expert systems, on the other hand, drive the inference strategy and interpret the constraints and restrictions imposed by the upper levels of the control hierarchy of the flexible manufacturing system. The level …

Integrating Scheduling And Control Functions In Computer Integrated Manufacturing Using Artificial Intelligence, Luis Carlos Rabelo, Sema E. Alptekin

Industrial and Manufacturing Engineering

Proper integration of scheduling and control in Flexible Manufacturing Systems will make available the required level of decision-making capacity to provide a flexibly-automated, efficient, and quality manufacturing process. To achieve this level of integration, the developments in computer technology and sophisticated techniques of artificial intelligence (AI) should be applied to such FMS functions as scheduling. In this paper, we present an Intelligent Scheduling System for FMS under development that makes use of the integration of two AI technologies. These two AI technologies — Neural Networks and Expert Systems — provide the intelligence that the scheduling function requires in order to …

Group Set-Up For Printed Circuit Board Assembly, Tali F. Carmon, Oded Z. Maimon, Ezey M. Dar-El

Industrial and Manufacturing Engineering

The current practice in the assembly of electronic components on printed circuit boards (PCBs) is serial production. a process characterized by very long set-up times. However, with the advent of efficient on-line process information .. new production control methods are now possible. This paper proposes a different production method, called the group set-up (GSU) method, which can significantly reduce set-up times. The traditional and the GSU production methods are compared, and it is shown that the GSU always performs better than the traditional method in terms of total production flow (throughput) and labour time However, the traditional method performs better …

A Systematic Transition To Flexible Manufacturing, Sema E. Alptekin, Daniel L. Webber

Industrial and Manufacturing Engineering

The transition from basic automation to flexible manufacturing is an expensive and tedious procedure. It requires meticulous planning and almost clairvoyant forecasting to insure that the initial flexibility obtained is sufficient to allow growth and expansion in the future. This paper will suggest a systematic and methodological approach to achieve optimal flexibility and describe the present results of its application to an ongoing system transformation. Conclusions based on existing levels of completion are presented along with identification of critical and non critical flexibility requirements. The considerations and steps taken are summarized in a procedural format which may then be applied …

Proposed Scheduling Methods For Printed Circuit Board Assembly, Tali Freed, Ezey M. Dar-El, Oded Z. Maimon

Industrial and Manufacturing Engineering

The current practice in the assembly of electronic components on printed circuit boards (PCB's) is serial production, a process characterized by very long set-up times.

However. with the advent of efficient on-line process information, new production control methods are now possible. This paper proposes two new production methods - the Grouped Set-up (GSU) method and the Sequence-Dependent Scheduling (SDS) method, which can significantly reduce set-up times.

It is shown that the GSU always performs better than the SDS method in terms of total production flow (throughput). while the SDS performs better than the GSU method in terms of work-in-process (WIP) …