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CISM COURSESAND LECTURES
Series Editors:
The Reetars of CISM Manuel Gqrcia Velarde - Madrid
Mahir Sayir - Zurich Wilhelm Schneider - Wien
The Secretary General of CISM Bernhard Sehreller - Padua
Former Secretary General of CISM Giovanni Bianchi - Milan
Executive Editor Carlo Tasso- Udine
This series presents lecture notes, monographs, edited works and proceedings in the field of the Mechanics, Engineering, Computer
Science and Applied Mathematics. Purpose of the series is to make known in the international scientific
and technical community results obtained in some of the activities organized by CISM, the International Centre for Mechanical Sciences.
INTERNATIONAL CENTRE FOR MECHANICAL SCIENCES
COURSESAND LECTURES - No. 437
AMST'02
ADVANCED MANUFACTURING SYSTEMSAND TECHNOLOGY
PROCEEDINGS OF THE SIXTHINTERNATIONAL CONFERENCE
EDITEDBY
ELSO KULIANIC UNIVERSITY OF UDINE
~ Springer-Verlag Wien GmbH
This book was printed with the contribution of Consorzio Universitario del Friuli and Regione Friuli Venezia Giulia
This volume contains 547 illustrations
This work is subjected to copyright. All rights are reserved,
wheter the whole or part of the material is concemed specifically those of translation, reprinting, re-use of illustrations,
broadcasting, reproduction by photocopying machine or similar means, and storage in data banks.
© 2002 by Springer-Verlag Wien Originally published by Springer-Verlag Wien New York in 2002
Softcover reprint of the hardcover 1st edition 2002
SPIN 10882242
In order to make this volume available as economically and as rapidly as possible the authors' typescripts have been
reproduced in the original forms. This method unfortunately has its typographicallimitations but it is hoped that they in no way
distract the reader.
ISBN 978-3-7091-2557-1 ISBN 978-3-7091-2555-7 (eBook)
DOI 10.1007/978-3-7091-2555-7
MATERIALS SCIENCE AND THE SCIENCE OF MANUFACTURING- INCREASING PRODUCTIVITY
MAKING PRODUCTS MORE RELIABLE AND LESS EXPENSIVE
ORGANIZERS
University of Udine- Faculty of Engineering- Department of Electrical, Managerial and Mechanical Engineering - Italy
Centre International des Seiences Mecaniques, CISM - Udine - Italy University of Rijeka- College of Engineering- Croatia
CONFERENCE VENUE
University of Udine - PALAZZO ANTONINI Via Tarcisio Petracco 8, Udine, Italy
PREFACE
Manufacturing a product is not difficult, the difficulty consists in manufacturing a product of high quality, at a low cost and rapidly.
Progress in materials and manufacturing sciences and technology, as weil as in intelligent machining systems, promotes an increase in productivity and a decrease of costs and production time without compromising the reliability of the products. In the new global and national condition the competitiveness of products depends in turn on their quality, which is becoming increasingly relevant.
The International Conference on Advanced Manufacturing Systems and Technology -AMST is held every third year. The First International Conference on Advanced Manufacturing Systemsand Technology AMST'87 was held in Opatija (Croatia) in October I987. The Second International Conference on Advanced Manufacturing Systems and Technology AMST'90 was held in Trento (Italy) in June I990. The Third, Fourth an Fifth Conferences on Advanced Manufacturing Systemsand Technology were alt held in Udine (Italy) asfollows: AMST'93 in April I993, AMST'96 in September I996 and AMST'99 in June 1999.
The Sixth International Conference on Advanced Manufacturing Systems and Technology - AMST'02, which was held in Udine in June 2002, aimed at presenting up-to-date information on the latest developments - research results and experience - in the field of machining of conventional and advanced materials, machine tools and flexible manufacturing systems, forming, nonconventional processes, robotics, measurement and control, quality, design and ecodesign, rapid prototyping, rapid taofing and manufacturing, materials and mechanics, thus providing an international forum for a beneficial exchange of ideas and furthering a favourable cooperation between research and industry.
Elso Kuljanic
HONOUR COMMITTEE
R. TONDO, President of Giunta Regione Autonoma Friuli - Venezia Giulia M. STRASSOLDO DI GRAFFEMBERGO, President of Provincia di Udine F. HONSELL, Rector of the University of Udine D. RUKAVINA, Rector of the University of Rijeka A. STELLA, Dean of the Faculty of Engineering, University of Udine S. CECOTTI, Mayor of Udine A. VALDUGA, President of the Associazione Industriali della Provincia di Udine G. FRAU, President of Consorzio Universitario del Friuli B. SCHREFLER, General Secretary of CISM G. BENEDETTI, Danieli & C. M. FANTONI, Fantoni Spa A. PITTINI, Gruppo Pittini R. SNAIDERO, Snaidero R. Spa
SCIENTIFIC COMMITTEE
E. KULJANIC, (Chairman), University of Udine, ltaly N. ALBERT!, University of Palermo, ltaly P. BARIANI, University of Padova, ltaly A. BUGINI, University of Bergamo, ltaly R. CEBALO, University of Zagreb, Croatia G. CHRISSOLOURIS, University of Patras, Greece B. FRANKOVIC, University of Rijeka, Croatia M.F. DE VRIES, University of Wisconsin Madison, U.S.A. R. IPPOLITO, Polytechnic of Torino, ltaly F. JOVANE, Polytechnic of Milano, ltaly I. KATAVIC, University of Rijeka, Croatia H.J.J. KALS, University of Twente, The Netherlands F. KLOCKE, T.H. Aachen, Germany F. LE MAITRE, Ecole Nationale Supeneurede Mechanique, France E. LENZ, Technion, Israel R. LEVI, Polytechnic of Torino, ltaly B. LINDSTROM, Royal Institute of Technology, Sweden G. MARINSEK, Centro Ricerche Fiat, ltaly J.A. Mc GEOUGH, University of Edimburg, UK M.E. MERCHANT, IAMS, Ohio, U.S.A. G .F.MICHELETTI, Polytechnic of Torino, ltaly B. MILCIC, INAS, Zagreb, Croatia T. NAKAGAWA, University OfTokyo, Japan S. NOTO LA DIEGA, University of Palermo, ltaly J. PEKLENIK, University of Ljubljana, Slovenia H. SCHULZ, T.H. Darmstadt, Germany
G. SPUR, T.U. Berlin, Germany N.P. SUH, MIT, Mass., U.S.A. H.K. TONSHOFF, University of Hannover, Germany B.F. von TURKOVICH, University of Vermont, U.S.A. K. UEDA, Kobe University, Japan A. VILLA, Polytechnic of Torino, Italy
ORGANIZING COMMITEE
E. KULJANIC (Chairman) F. MIANI (Secretary) G. BIANCHI, C. BANDERA, F. DE BONA, S. FILIPPI, A. GASPARETTO, M. GIOVAGNONI, S. MIANI, G. CUKOR, M. SORTINO
SUPPORTING ORGANIZATIONS
Giunta Regione Autonoma Friuli - Venezia Giulia, Provincia di Udine, Comune di Udine, University of Udine, Consorzio Universitario del Friuli, Danieli & C., Fantoni Spa, Gruppo Pittini, Snaidero R. Spa, Fondazione Cassa di Risparmio di Udine e Pordenone, Comitato per la promozione degli studi tecnico scientifici, Centro Convegni ed Accoglienza, Pietro Rosa T.B.M., FAMUP, ONRIFO Office of Naval Research International Field Office, US Navy.
CONTENTS
Preface
Trends in Mannfactoring
The Dynamic Cluster Structures: a New Manufacturing Paradigm for Production of High-Tech Product
by J. Peklenik
Recent Development and Trends in Tool Condition Monitaring by E. Kuljanic and M. Sortino
Comprehensive Simulation of Manufacturing Processes by H. K. Toenshoff, M. Clausen and K. Tracht
Knowledge Management- an Essential Contribution to Company's Success by H. Schutz
Industrial Experiments - Theory and Practice by R. Levi and D. Romano
Disassembly for Recycling, Maintenance and Remanufacturing: State of the Art and Perspectives
by M. Santochi, G. Dini and F. Failli
Analysis of some Innovative and Flexible Sheet Forming Processes by N. Alberti and F. Micari
Machining Processes
lmprovement of the Surface Texture Quality of Milled Dies and Molds by A. Moisan, M. Boujelbene, B. Brenier and A. Fahre
Machining Abrasion-resistant Hard-facings with PCBN Tools by E. J. Brookes, R. D. James, C. Shutt and C. J. Taylor
Page
1
15
37
49
61
73
91
105
113
Machining Process lmprovement by Practical Tests in Shop Floor by N. L. Coppini and E. A. Baptista 121
Crankshaft Manufacturing on Machining Centres- Turn-miHing and Deep Hole Drilling by K. Wienert and H. Loebbe 129
A Contribution to the Strain-Hardening Process Analysis of Hardened Steel During HighSpeed Machining
by S. Dolinsek and S. Ekinovic 137
Tool Flank Wear Prediction Using the Force-Time Measurement in Tuming by G. Cukor and E. Kuljanic 143
Metal Matrix Composites - MMC - Turning: Comparison of Tool Materials by C. Borsellino, S. Lo Casto, E. Lo Valvo and V. F. Ruisi 151
Application of a Rotating Dynamometer for Cutting Force Measurement in Milling by E. Kuljanic, M. Sortino and F. Miani 159
Simulation of Chip Formation in an Orthogonal Cutting Process Using FEM by G. Giorleo, R. Teti, A. Langella, D. D'Addona and U. Prisco 167
Study of Macro and Micro Quality Determinants of Pieces Obtained from Optimized Drilling Process
by A. Lima and M. Vieira Jr 179
Experimental Test for Tool Life Prediction in Turning by M. Nicolich 185
Technological Models Based on Grinding Wheel and Workpiece Characteristic in the Grinding Process of MMCs
by A. Di Ilio and A. Paoletti 193
Optimisation of Process Conditions Using "Experiments with Mixtures" by N. Sakic, V. Panic and I. Dubravec 203
Selection of Optimal Cutting Condition in Computer Aided Machining by Genetic Algorithms
by V. Gecevska, V. Pavloski 209
Machine Tools and Flexible Mannfactoring Systems
An Alternative Approach to Elasto-kinematic ModeHing of Machine Tool Structures by H. K. Tonshoff, S. Rehling and K. Tracht 215
Reliability and Availability of Complex Production Systems by H.P. Wiendahl and M. Hegenscheidt 225
Modem Tendencies in Rotary Transfer Machines by E. Gentili, C. Giardini, R. Pasquino and P. Quinzani 233
The Machine Tool's Next Step: Step NC by M. Weck and J. Wolf 241
An Automated System for Dimensional Control Based on Computer Vision by C. Borsellino, E. Lo Valvo and V.F. Ruisi 249
Stiffness of CNC Machine Tool Feed Drives by Z. Pandilov and V. Dukovski 259
A Set of Criteria for Supply Chain Design by A. Villa 267
Applying of Typical Technological Operations in the Single Production by G. Simunovic, N. Majdandzic, K. Simunovic and R. Lujic 275
Process Planning Application and Internet Connection by P. Cosic , D. Sever and S. Milinovic 283
E-business Requires Simulation of Logistic Processes by W. Sihn, T.D. Graupner, U. Mussbach-Winter and H. Wiedenmann 291
Tool Path Optimization by High Speed Machining by J. Kopac and T. Rohlek 299
Uncertainty Analysis and Optimization of a FMS by Experimental Design Applied to
Simulation by B. Palumbo, F. Caiazzo and V. Sergi 307
Computer Aided Determination of Feasibility of Work Operation on Machines in Flexible Manufacturing Systems
by /. Pahole 317
An Integrated Tool for Geometrical Reconstruction of Functional Surfaces by D. Comelli, G. Concheri and R. Meneghello 321
Forming
Cost-efficient Manufacturing by Employing Incremental Forming Processes by P. Groche, M. Jöckel, C. Rachor and T. Rathmann
The Use of a Neural Network in Predicting the Mechanical Properties of Low Carbon Steels After Hot Rolling
by F. Caiazzo, F. Memola Capece Minutolo, R. Pasquino and V. Sergi
FEM Model Computing Large Deformation in Metal Sheet Forming by High PowerBeam
by G. Casalino, G. De Astis and A. D. Ludovico
Investigation of the Effects ofThermal and Mechanical Fatigue of Dies in Hot Forging Through a New Simulative Laboratory Test
by G. Berti, S. Bruschi, S. Masiero, M. Monti and M. Zimmitti
Flow ModeHing of AA 6082 Aluminium Alloy by C. Bruni, A. Forcellese and F. Gabrielli
Simulation of Welding Conditions in Porthole Die Extrusion by L. Donati and L. Tomesani
Towards a General Quality Indicator for Adaptive FEM Simulation of Sheet Forming Processes
by M. Strano and L. Carrino
The Main Principles of Forming Integral Panels used in Modem Shipbuilding Industry
by R. Markovina
329
337
347
357
367
375
383
393
The Main Principles of Using and Forming Integral Panels in Modem Shipbuilding lndustry
by R. Markovina
Design of the Tube Roll Forming Process Through an Heuristic Algorithm by G. Celano, A. Costa, S. Fichera and L. Fratini
Design Issues for Micro-formed Sheet Metal Components by D. Antonelli and P. Chiabert
Finite Elastoplasticity in Plane Strain Cold Rolling Problem by J. Brnic, M. Canadija and G. Turkalj
Nonconventional Processes
Bumishing Versus Grinding For Automotive Parts
401
409
417
425
by L. Luca, I. Marinescu and S. Neagu-Ventzel 433
Evaluation of Warpage of Injection Moulded Parts Using RE and FEM Approaches by L.M. Galantucci, G. Percoco, R. Spina and L. Tricarico 441
Analyzing the Warpage in the Injection Molding Using SLS Tool Inserts by J. Gabor, J. Kovacs 449
Orbital Electrochemical Machining of Electrodischarge Machined Surfaces by Z. Sadollah Bamerni and H. El-Hofy 457
Design of Low Expansion Composites with Reduced Process lnduced U ncertainties
by F De Bona, A. Gambitta and A. Soma' 465
Analysis of High Power C02 Dual Beam Laser Welding by E. Capello,· P. Chiarello, E. Piccione and B. Previtali 473
Filament Winding: an Integrated Simulation Environment for Automated Cell Programming
by A. Anglani, F Nucci and A. Spagnolo 481
Methods for Welding Quality Improvements by D. Pavletic 491
Radial Segregation of Workpiece in Barrel Finishing by A. Boschetto and F. Veniali 499
Shape Machining of Aerospace Composite Components Using Non-Traditional Abrasive
Waterjet Cutting Processes by X. Zheng, L. Chen, E. Siores, P. Steele and P. Crothers 507
Comparative Studies of Brush Elettrodischarge Machining with Electrodes of
Alloy Steel and Tungsten by S. Spadlo 515
Robotics, Measurement and Control
Measurement System for mN Forces by G. Manzoni and P. Miotti 525
Application of Statistical Process Control to Continuous Processes by G. Celano, A. Costa and S. Fichera 531
Design and Implementation of a Cartesian Robot by A. Gasparetto and G. Rosati 539
Design of a Robotic Wrist for Biomedical Applications by A. Gasparetto and A. Biason 545
Developement and Performance Assessment of a Laser Triangulation Scanner for
Digitizing Shoe Lasts by N. De Rossi, A. Rossi, A. Trevisani and V. Zanotto 553
Design and Development of a Vision Based Leather Trimming Machine by M. Lanzetta and G. Tantussi 561
Accuracy of a 3D Vision System for Inspection of Complex Geometry by S. Carmignato, E. Savio and L. De Chiffre 569
Autonomaus Agent System Using Dispatehing Rules in the Negotiation Protocol by L. Castelli, A. Nicola, R. Pesenti and W. Ukovich 577
Robustness Analysis of Frequency-Domain PI Controller Design Procedures by W. Krajewski, A. Lepschy, S. Miani and U. Viaro 585
A New Approach to the Use ofVibration Signals in Tool-Wear Monitaring in High Speed Metal Turning
by D. E. Dimla Snr and M. Sortino 593
Quality, Design and Ecodesign
Market Value of Recycled Material Mixes: a Key Parameter for Designing for Recycling by G. Berti, W.A. Knight and G. Lucchetta 601
Identification and Assessment of Non Conformity Parameters for Quality Cost Reduction by M. Boscolo and E. Padoano 609
Minimizing the Cost of Quality: an Innovative Sampling Plan by C. Giardini and G. Valentini 617
Optimizated Design of Notch Shapes for Microfabricated Compliant Mechanisms by E. Dalla Serra, F. De Bona and M. Munteanu 625
QFD And TM: a Pragmatical Approach by E. Gentili and F. Galetto 633
Datums Concepts by ASME and ISO standards by /. Cristofolini 641
Quality Decisions and ISO 9000: 2000 Principles by F. Galetto 649
Failure Scenario FMEA: Theoretical & Applicative Aspects by E. Locatelli, N. Valsecchi, G. Maccarini and A. Bugini 657
From Plastic Waste to Recycled-content End Products: the Chair lndustry Case by A. Meneghetti, G. Nardin and P. Simeoni 665
Quality Product Controls of Silicon Pixel Sensors for a High Energy Particle Physics Experiment
by G. Cabras, D. Cauz, D. Cobai, M. Cobal-Grassmann, B. De Lotto, C. Del Papa, H. Grassmann and L. Santi 673
Evaluation of DFX Tools in Ecodesign by M. Kljajin 679
Time Lag Error of Inventory in Inflation by J. Mrsa 687
Collaborative Design and Manufacturing of a Customizable Voice Prosthesis by G. Concheri, S. Filippi, R. Meneghello, C. Miani and D. Comelli 695
Analysis of Geometrical Distorsions of Spur Shafts due to Heat Treatments by L. D 'Angelo 705
Benchmarking of Attribute Two-level Sampling Schemes with Zero Acceptance Number by M. Dassisti 713
Rapid Prototyping, Tooling and Mannfactoring
Economic Evaluation of Alternatives for Microelectronics Lithography Processing by Z. Wang and W.A. Knight 723
Ceramic Components Built by Stereolithography by C. Esposito Corcione, A. Greco, A. Licciulli, M. Martena and A. Maffezzoli 731
CT-Based Reverse Engineering and Rapid Prototyping: Experiences in Different Application Domains
by C. Bandera, M. Felice and S. Filippi 741
Exploiting the Evaluation of RP Artifacts to Update Knowledge in Design Guidelines by C. Bandera, S. Filippi, F. Miani and G. Toneatto 749
A Contribution to the Analysis, Characterization and lmprovement of Surface Properties Generated by DMLS For RT
by M. Vezzani, A. 0. Andrisano, R. Groppetti, P. Onesti, A. Rossi and A. Scrivani 757
Laser Sintering of Sand and its Application in Rapid Tooling by X.H. Wang, J.Y.H. Fuh, Y.S. Wong and Y.X. Tang 771
Direct Laser Sintering of Cu-based Metallic Powder for Injection Moulding by H.H. Zhu, J. Y.H. Fuh and L. Lu
Materials and Mechanics
Molecular Dynamic Simulation of Nanoindentation of Silicon Carbide by Diamond Tip
779
by A. Noreyan, I. Marinescu and J. Amar 785
Influence of the Hot Isostatic Pressing on the Mechanical Behaviour of CVD-Coated Hardmetals
by M. Tolazzi, S. Kursawe and H. G. Sockel 793
Effect of Crystal Grientation on Surface Integrity by J. Prohaszka, J. Dobranszky, M. Horvath andA.G. Mamalis 801
Sintered Alloys Mechanical Properties Simulation with Cell Method by F. Cosmi 809
Some Properties of Nitrided Tool Steels by B. Smoljan 817
Fillet Stress Related to Non-uniformly Loaded Gear Tooth Geometry
~a~ro~ rn
Use of Ultrasound to Detect Internat Defects of Spheroidal Graphite Cast Iron Products by E. Ceretti, A. Attanasio and C. Giardini 833
Milling Tests of Austenitic Stainless Steel Without Nickel by L. Zaquini and P. Reusser 843
Uncertainty Management for Productive Process Control by M. Russo and D. Freguia 851
Micromilling - High Potential Technology for Micromechanical Parts by D. Spath, H. Tritschler, L. Bisehoffand W Schutz 859
FEM Analysis in a Machining Center by B. Cecchini, R. Pavan, D. Ruffati and M. Tellan, 865