Institute for Systems Research
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Item Characterization of the Surface Cracking Formed during the Machining of Ceramic Material(1995) Zhang, G.M.; Ng, S.; Le, Dung T.; ISRThis paper presents a method to characterize the surface cracking formed during the machining of ceramics material. Ceramic specimens are prepared under two different machining environments, dry and submersion. An environmental scanning electron microscope is used to obtain high-magnification images of machined surfaces. Reconstruction of the surface texture in a three-dimensional space is made by scanning the images and using graphics software to obtain detailed and informative spatial views of the machined surface. The visualized surface cracks provide quantitative information on their size and shape. Two performance indices are proposed to characterize the distribution of surface cracks induced by machining in terms of the density and crack depth with reference to the machined surface. As a case study, the developed nondestructive evaluation method is used to assess the effectiveness of using the submerged machining to process ceramic material. The obtained results present a clear picture illustrating the capability of controlling the crack formation during the submerged machining.Item Building MRSEV Models for CAM Applications(1993) Gupta, Satyandra K.; Kramer, Thomas R.; Nau, D.S.; Regli, W.C.; Zhang, G.M.; ISRIntegrating CAD and CAM applications, one major problems is how to interpret CAD information in a manner that makes sense for CAM. Our goal is to develop a general approach that can be used with a variety of CAD and CAM applications for the manufacture of machined parts.In particular, we present a methodology for taking a CAD model, extracting alternative interpretations of the model as collections of MRSEVs (Material Removal Shape Element Volumes, a STEP-based library of machining features), and evaluating these interpretations to determine which one is optimal. The evaluation criteria may be defined by the user, in order to select the best interpretation for the particular application at hand.
Item Interpreting Product Designs for Manufacturability Evaluation(1993) Gupta, Satyandra K.; Nau, D.S.; Zhang, G.M.; ISRThe ability to quickly introduce new quality products is a decisive factor in capturing market share. Because of pressing demands to reduce lead time, analyzing the manufacturability of the proposed design has become an important step in the design stage. In this paper we present an approach for evaluating the manufacturability of machined parts.Evaluating manufacturability involves finding a way to manufacture the proposed design, and estimating the associated production cost and quality. However, there often can be several different ways to manufacture a proposed design - so to evaluate the manufacturability of the proposed design, we need to consider different ways to manufacture it, and determine which one best meets the manufacturing objectives.
In this paper we describe a methodology for systematically generating and evaluating alternative operation plans. As a first step, we identify all machining operations which can potentially be used to create the given design. Using these operations, we generate different operation plans for machining the part. Each time we generate a new operation plan, we assign it a manufacturability rating. The manufacturability rating for the design is the rating of the best operation plan.
We anticipate that by providing feedback about possible problems with the design, this work will be useful in providing a way to speed up the evaluation of new product designs in order to decide how or whether to manufacture them.
Item Generation of Machining Alternatives for Machinability Evaluation(1992) Gupta, Satyandra K.; Nau, D.; Zhang, G.M.; ISRThis paper presents a new methodology for evaluating the machinability of a machined part during the design stage of the product development cycle, so that problems related to machining can be recognized and corrected while the product is being designed. Our basic approach is to perform a systematic evaluation of machining alternatives throughout each step in the design stage. This involves three basic steps: (1) generate alternative interpretations of the design as different collections of machinable features, (2) generate the various possible sequences of machining operations capable of producing each interpretation, and (3) evaluate each operation sequence, to determine the relevant information on achievable quality and associated costs. The information provided by this analysis can be used not only to give feedback to the designer about problems that might arise with the machining, but also to provide information to the manufacturing engineer about alternative ways in which the part might be machined.Item Chemo-Mechanical Effects on the Efficiency of Machining Ceramics(1992) Zhang, G.M.; Hwang, Tsu-Wei; Anand, Davinder K.; ISRThis paper presents an experimental study of the turning of a ceramic material - aluminum oxide (A12O3). Emphasis is given to gain a comprehensive understanding of the cutting mechanism. This study explores the utilization of cutting fluids with chemical additives to develop a novel machining process. The machining tests were performed on a CNC lathe. Polycrystalling diamond compact tools were used. The cutting force during machining was measured using an instrumented tool holder as a dynamometer. The surface finish was inspected using a profilometer. SEM technique was used to study the mechanism of the surface formation in microscale. Results from this experimental study provides rich information on the cutting mechanisms during ceramics machining and the chemo-mechanical effects on the machining efficiency.Item Concurrent Evaluation of Machinability during Product Design(1992) Gupta, Sandeep K.; Nau, D.; Zhang, G.M.; ISRThis paper presents a new methodology of evaluating the machinability of a machined part during the design state of the product development cycle, so that problems related to machining can be recognized and corrected while the product is being designed. Our basic approach is to perform a systematic evaluation of machining alternatives throughout each step in the design stage. This involves three basic steps: (1) generate alternative interpretations of the design as different collection of machinable features, (2) generate the various possible sequences of machining operations capable of producing each interpretation, and (3) evaluate each operations sequence, to determine the relevant information on achievable quality and associated costs. The information provided by this analysis can be used not only to give feedback to the designer about problems that might arise with the machining, but also to provide information to the manufacturing engineer about alternative ways in which the part might be machined.Item Evaluating Product Machinability for Concurrent Engineering(1992) Nau, D.S.; Zhang, G.M.; Gupta, Satyandra K.; Karinthi, Raghu R.; ISRDecisions made during the design of a machined part can significantly affect the product's cost, quality, and lead time. Thus, in order to address the goals of concurrent engineering, it is important to evaluate the machinability of the proposed design, so that the designer can change the design to improve its machinability, To determine the machinability of the part, all of the possible alternative ways to machine the part should be generated, and their machinability evaluated. This chapter describes the techniques we have developed to do this automatically.The information provided by these techniques will prove useful in two ways: (1) to provide information to the manufacturing engineer about alternative ways in which the part might be machined, and (2) to provide feedback to the designer identifying problems that may arise with the machining.