TELEMANUFACTURING IN CONCURRENT ENGINEERING

1
TELE-MANUFACTURING IN CONCURRENT ENGINEERING

• A COURSE MODULE IN CONCURRENT ENGINEERING FOR
  GATEWAY EEC PROJECT

Dr. Jack Zhou Department of Mechanical
Engineering and Mechanics Drexel University,
Philadelphia, PA
2
Tele-Manufacturing In Concurrent Engineering-A
Course Module
Course Description This course will introduce a
new concept and methodology-Concurrent
Engineering (CE) into design and manufacturing
curriculum. A latest technology,
Telemanufacturing in CE , which integrates 3-D
solid modeling, CAD/CAM, Rapid prototyping,
Telecommunication and networking into an
intelligent manufacturing process system, will be
taught systematically. A comprehensive
application project (example) Design and
Manufacturing of a Race Car Spindle will be
illustrated to further understand
Telemanufacturing in CE. Course Length This is
a two hour lecture, three hour reading and two
hour homework course module.
3
Tele-Manufacturing In Concurrent Engineering-A
Course Module

• Reading Materials
• Jack Zhou etc., Concurrent Engineering Concept
  Applied in Concurrent Education and
  ResearchProceedings of 3rd International
  Conference in Concurrent Engineering Research and
  Applications, August, 1996, Toronto, Canada.
• Tien-C. Chang etc., Computer-Aided Manufacturing,
  chapters 6 and 8, Prentice
• Hall, 92
• Michael Bailey, Tele-manufacturing Rapid
  Prototyping on the Internet, IEEE
• Journal of Computer Graphics and Applications,
  November 1995, pp. 20-26.
• Homework
• Answer the following
• 1. How important do you think Concurrent
  Engineering and Telemanufacturing are in
  industry? in university? What are the
  benefits/drawbacks of Concurrent Engineering and
  Telemanufacturing.
• 2. What is the advantage of rapid prototyping
  compares to conventional methods, can rapid
  prototyping provide avenues to rapid
  fabrication/manufacturing?
• 3. What are the major tools available to
  implement Concurrent Engineering/Telemanufacturing
  . What is the availability of these tools.

4
INTRODUCTION

• What is Concurrent Engineering?
• What is Concurrent Education?
• What is Tele-Manufacturing in Concurrent
  Engineering?

5
What is ...?
6
CONCURRENT ENGINEERING

• Definition

Simultaneous or parallel consideration of all
facets of the product development process
(including design, analysis, manufacturing,
testing, quality control and marketing) for the
purpose of reducing the time to market, cutting
down cost, and improving quality.
7
SEQUENTIAL AND PARALLEL ENGINEERING
8
BENEFITS FROM CONCURRENT ENGINEERING

• Surveys shows that Concurrent Engineering can
  reduce the time to market 55, return on assets
  70 higher, and improve overall quality 350
  higher

9
CONCURRENT EDUCATION

• Definition

Concurrently introducing latest science and
technology into the new curriculum development of
our high education system, breaking the barriers
of traditional sequential (i.e.. step by step)
and isolated curricula, but integrating
multi-stages of curricula and interdisciplinary
teachings into classroom.
10
(No Transcript)
11
BEST PRACTICE IN CE

• To better prepare our engineers and to enhance
  global competitiveness of U.S. industry, the
  industrys top 20 Best Practices skills should
  be taught at U.S. universities.
• Concurrent Engineering integrates the most
  technologies and skills of the top 20 Best
  Practice and is an ideal course to train our new
  generation of engineers.

12
TELE-MANUFACTURING IN CONCURRENT ENGINEERING
Todays manufacturing is not only parallel
processes, but also a global activity. Taking the
advantages of computer networking and
telecommunication, a global range
tele-manufacturing is possible. Boeing 777 is a
good example of CE and Tele-manufacturing. More
than 10,000 people and 200 design groups were
involved in the creation of the new plane, which
is assembled with four million parts provided
from all over the world,
13
A Typical Example of Concurrent Engineering
Application for Boeing 777
A short Movie 21st Century Jet
14
Where To Go.?
15
ADVANCED TECHNOLOGIES, SKILLS TOOLS IN TM AND CE

• 3-D Solid Modeling Based CAD/CAM/CAE
• Integrated Manufacturing Systems
• Stereolithography RP Machine and CNC Machine
• Computer System Networking

16
A TYPICAL CAD/CAM/CAE SOFTWARE FOR CE AND
TELE-MANUFACTURING
17
INTEGRATED MANUFACTURING SYSTEM FOR CE TM
APPLICATIONS
18
A Stereolithography Rapid Prototyping Machine
19
Principle of SLA Machine
20
How to Create an STL File and File Compression
HOW TO CREATE AN STL FILE 1. Create solid model
in Master Modeler 2. Change to Rapid Prototype
task 3. Pick Create Prototype command icon 4.
Pick the part you want to prototype (a Create
Prototype form will show up) 5. Select an
appropriate Prototype Device 6. Select Part
Positioning to Center 7. Name Output File and
path (If no path is specified, it will be in
your current working directory) 8. Type in
appropriate value for Absolute Facet
Deviation 9. Pick Show Facets button to see the
facets under current setting 10. Change settings
if there is any error message in the last
step 11. Pick OK or Apply button, the stl file
with an extension .stl will be
created. FILE COMPRESSION To compress a file,
at UNIX prompt, type compress filename(s), or
compress -v filename(s), which will display the
percentage of reduction for each compressed
file. To decompress a file, type uncompress
filename(s).
21
Desk Top CNC Machining
22
Principle of CNC Machining
23
(No Transcript)
24
Integrated Remote Manufacturing
Drexel University
SUN OR HP WORKSTATION
I-DEAS PRO/ENGINEER MASTERCAM AUTOCAD
SANDERS 3-D DESK MODELER
Intergrated Remote Manufacturing
TelePrototyping
TeleManufacturing
PRO ENGINEER
3D SYSTEMS SLA-250 RAPID PROTOTYPING
MASTERCAM
CINCINATTI CNC MACHINING CENTER
3D SYSTEMS SLA-250 RAPID PROTOTYPING
FADAL 5-AXIS MACHINING CENTER
ATT Bell Laboratories (New Jersey)
State University of NY at Farmingdale
New Jersey Institute of Technology
25
AN EXAMPLE OF TELE-MANUFACTURING IN CE

• A Race Car Spindle Design, Analysis,
• Tele-Rapid Prototyping, and Tele-CNC Machining

26
Race Car Competition
27
Dragon Race Car Movie
28
Our CE Wheel Used in ConcurrentEducation and
Race Car Project
29
Rear Wheel Spindle Assembly of FSAE Race Car
30
Boundary Conditions and Applied Force in FEA
31
FEA Results-Stress and Deformation
32
Manufacturing Simulation on I-Deas
33
Tele-Manufacturing Procedure
The STL file was transferred to the ATT Bell Lab
through internet using File Transfer Protocol
(FTP), and by using their rapid prototyping
machine a spindle prototype was made. After
trials and errors , the final G-code was FTPed to
SUNY Farmingdale in New York, and then a aluminum
spindle was manufactured using their CNC
machining center in 1.5 hrs.
34
CNC Tele-Manufacturing Between Drexel and SUNY
Farmingdale
CNC Machining the Spindle
35
CNC Tele-Manufacturing Between Drexel and SUNY
Farmingdale
Automatic Tool Change
36
CONCLUSION
Concurrent Engineering as a new methodology and
also a new technology has been applied in our
teaching and research. Concurrent Education as a
new concept has been introduced to our curriculum
reformation. As an example, a research project
entitled Design and Manufacturing of a Rear
Wheel Spindle and its Assembly for the FSAE Race
Car was conducted by using CE and concurrent
education, which resulted in saving time (five
weeks students school time was used), higher
quality (a safety factor ten was obtained from
FEA), reducing the cost (the cost reduced from
120.31 to 50.31 per part), and the most
importantly trained a new generation of CE force.