Institute for Systems Research

Using a systems engineering approach, a computer-based surface integrity assessment methodology is formulated. It combines the most recently developed image processing technology with computer graphics while incorporating the principles of fracture mechanics. Microhardness testing is used to study material properties related to machining. Four types of material selected are human enamel, Dicor-MGC, HCC Dentine, and HCC Enamel. Three- dimensional visualization of the surface impressions is achieved using an environmental scanning electron microscope and an atomic force microscope. Machining experiments are conducted to study the surface integrity, including surface finish, micro- cracking, and edge chipping. Analytical investigation correlates these surface responses to the machining parameters, such as spindle speed, feed rate, and the depth of cut, to seek a parametric region in which quality of machined ceramic components can be ensured. Surface integrity performance indices such as surface roughness, cavity density, and chip aspect ratio are proposed to quantify such evaluations.

Major contributions of this thesis research include the development of the combined SEM- AFM stereophotography method. The high resolution achieved with this method ensures coverage of rich information on the surface texture formed during machining. Specific findings of this thesis research include the identification of micro-mechanics of fracture occurred during the material removal process, and a good understanding of possible influences of the microstructures on the machining performance.

In this paper, we describe our current work towards the integration and enhancement of the capabilities of EDAPS and EXTRA. We integrate EXTRA's functionality with the initial design step of EDAPS. in the resultant system, the user, supported by an enhanced tradeoff analysis capability, can select and describe a promising preliminary design and process plan based on the analysis of a variety of alternatives from both an electrical and mechanical perspective. This preliminary design is then subjected top further analysis and refinement using existing EDAPS capabilities. In addition to the integration of these two systems, specific new functions have been developed, including tradeoff analysis over a much broader set of criteria, and the ability of the tradeoff module to query the process planner to determine costs of individual options.

Evaluating the manufacturability of a proposed design involves determining whether or not it is manufacturable with a given set of manufacturing operations - and if so, then finding the associated manufacturing efficiency. In this research, the design is represented as a solid model. The tolerance and surface finish information is represented as attributes of various faces of the solid model. Machining features are used to model the available machining operations Since there can be several different ways to manufacture a proposed design, this requires considering alternative ways to manufacture it, in order to determine which one best meets the design and manufacturing objectives.

The approach developed in this thesis is based on the systematic exploration of various machining plans. The first step is to identify all machining features which can potentially be used to machine the given design. Using these features, different machining plans are generated. Each time a new plan generated, it is examined to find whether it can produce the desired design tolerances. If a plan is found to be capable of meeting the tolerance specifications, then its rating is computed. If no machining plan can be found that is capable of producing the design, then the design cannot be machined using the given set of machining operations; otherwise, the manufacturability rating of the design is computed. Since various alternative ways of machining the part are considered in this approach, the conclusions about the manufacturability are more realistic compared to the approach where just one alternative is considered.

It is anticipated that this research will help in speeding up the evaluation of new product designs in order to decide how or whether to manufacture them. Such a capability will be useful in responding quickly to changing demands and opportunities in the marketplace.

In this paper, we survey of current state of the art in automated manufacturability analysis. We describe the two dominant approaches to automated manufacturability analysis and overview representative systems based on their application domain. Finally, we attempt to expose some of the existing research challenges and future directions.

In this paper, we provide a survey of current state of the art in automated manufacturability analysis. We present the historical context in which this area has emerged and outline characteristics to compare and classify various systems. We describe the two dominant approaches to automated manufacturability analysis and overview representative systems based on their application domain. We describe support tools that enhance the effectiveness of manufacturability analysis systems. Finally, we attempt to expose some of the existing research challenges and future directions.