INTEGRATED DESIGN AND MANUFACTURING IN MECHANICAL ENGINEERING '98

INTEGRATED DESIGN AND MANUFACTURING IN MECHANICAL ENGINEERING '98 Proceedings of the 2nd IDMME Conference held in Compiegne, France, 27-29 May 1998

Edited by

JEAN-LOUIS BATOZ Departement GSM, Universite de Technologie de Compiegne, France

PATRICK CHEDMAIL Institut de Recherche en Cybernetique de Nantes, Ecole Centrale de Nantes, France

GERARD COGNET E.N.S.A.M., Paris, France

and

CLEMENT FORT IN Department of Mechanical Engineering, Ecole Polytechnique de Montreal, Canada

Springer-Science+Business Media, B.V.

A C.I.P. Catalogue record for this book is available from the Library of Congress.

ISBN 978-90-481-5342-8 ISBN 978-94-015-9198-0 (eBook) DOI 10.1007/978-94-015-9198-0

Printed on acid-free paper

All Rights Reserved © 1999 Springer Science+Business Media Dordrecht Originally published by Kluwer Academic Publishers in 1999.

Softcover reprint of the hardcover 1 st edition 1999 No part of the material protected by this copyright notice may be reproduced or utilized in any form or by any means, electronic or mechanical, inc1uding photocopying, recording or by any information storage and retrieval system, without written permission from the copyright owner.

TABLE OF CONTENTS

Preface ..................................................................................................................... xiii Acknowledgements ................................................................................................. xv Introduction ............................................................... .............................................. XVll

Chapter 1 : STRUCTURAL ANALYSIS OF MECHANICAL PARTS ................... .

Helical buckling of an optical fibre composite cable introduced by pushing in a duct ..................................................................................................... 3 H. BOULHARTS, L. RIVIERRE, lL. BILLOET, O. POLIT,A. PECOT

and lL. CAMPION

Simulation and optimization ofthermomechanical sollicitations ........................... 11 V. BOGARD and PH. REVEL

Localization of collapse mechanisms for simplified vehicle crash simulation ....... 19 D. CORNETTE, lL. THIRION, E. MARKIEWICZ, P. DRAZETIC and Y. RA VALARD

Computational code for a simplified analysis ofplate structures............................ 27 XIO-LING DENG, C. HOCHARD, G. HUBERT and F. LEBOUVIER

Aircraft engine blades-casing contact study ............................................................ 35 GUILLOTEAU, E. ARNOULT, B. PESEUXahd M BERTHILLIER

Design of a superconducting quadripole prototype: using substructuring to take contact into account ..................................................................................... 43 C. BLANZE, L. CHAMPANEY and P. VEDRINE

Theoretical and numerical study of a coupler for crashworthy design of a TGV power car............................................. .................................................... 51 JEONG SEO KOO, ZHIGIANG FENG, M. DOMASZEWSKI and F. RENAUDIN

Global numerical model of automobile gearboxes.................................................. 59 A. BOURDON, K YAKHOU and D. PLAY

Smart materials design: the Mechatronic approach................................................ 67 C. DELEBARRE, P. BLANQUET, T. DEMOL, D. COUTELLIER and E. DELACOURT

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Chapter 2 : COMPUTATIONAL MECHANICS AND OPTIMUM DESIGN OF STRUCTURES .................................................................................... 75

Machining optimization of quenched parts ...... ............................................. .......... 77 A. ABISROR, F. CONGOURDEAU, G. MARIN, J.M. ROELANDT AND N. V ALLINO

Optimization of a passive safety device by means of the response surface methodology .. ......... ..... ..... ......... ......... ................................... ..... ..... ....... .... 85 G. BELINGARDI and M. AV ALLE

Optimal design of mechanical components with genetic algorithms ............. ......... 93 L. GIRAUD and P. LAFON

Design of materials with specific elastic properties using shape optimization method................................................................................................ 101 SHUTIAN LIU, YUANXIAN Gu and GENDONG CHENG

Shape optimization and adaptativity ofaxisymmetrical shells undergoing geometric nonlinearities . ............... ........ ...... ............ .... ....... ..... ..... ..... ... 109 H. NACEUR, S. TRIKI, J.L. BATOZ AND C. KNOPF-LENOIR

Topological optimization of shells with non uniform thickness ... ......... ... ....... ... .... 117 E. PAGNACCO and J. E. SOUZA DE CURSI

Non-deterministic methods for productlprocess analysis and robust design - the «possibilistic» approach.................................................... 125 V. BRAIBANT, F. DELCROIX, A. OUDSHOORN and C. BOYER

Design of an automatic topology/geometry optimization software......................... 133 S. BEUZIT and A. HABBAL

Chapter 3 : FINITE ELEMENT SOLVERS. MESHING TECHNIQUES COMPUTER AIDED GEOMETRY ......................................................................... 141

Intelligent objects for pre-processing in a mechanical finite element software ...... 143 P. BOMME and TH. ZIMMERMANN

A message passing paradigm for distrihuted design and simulation ofmechanical systems............................................................................................. 151 P. BREITKOPF AND Y. ESCAIG

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FEM/CAD system architecture for shape optimization of3D parts........................ 159 A. MERROUCHE and C. KNOPF-LENOIR

2D Mesh and geometrie adaptations using an apriori model of mechanical behavior ................... ......... ............................................................... 167 PH. VERON, L. FINE, F. NOEL and lC. LEON

On the automation of non-linear behavioral structural analysis. Guidance and quality control .................................................................................. 175 J.P. PELLE and D. RYCKEL YNCK

Computational geometry in the preprocessing of point clouds for surface modeling................................................................................................ 183 RUIZ OSCAR and POSADA JORGE

Polyhedron partitioning dedicated to a hierarchical meshing technique ................. 191 F. MAZA, F. NOEL AND lC. LEON and F. SILLION

A declarative approach for geometry and topology : a new paradigme for CAD-CAM systems........................................................................................... 199 A. CLEMENT, A. RIVIERE and PH. SERRE

Piecewise cubic interpolation for reverse engineering.......... .......... ....... ............ ..... 207 G. PRADES, J.L. CAENEN, Y. MINEUR and J.M. CASTELAIN

Chapter 4: MODELING AND SYNTHESIS OF MECHANISMS .......................... 215

Component mode synthesis in the design and the optimisation of mechatronic systems... ............................................................................................. 217 P. DE FONSECA, H. V AN BRUSSEL and P. SAS

The kinematics design of a 3-dof hybrid manipulator............................................. 225 D. CHABLAT, PH. WENGER and J. ANGELES

Geometrie synthesis ofmanipulators under kinematic constraints ......................... 233 S. GUERRY, B. OUEZDOU and S. REGNIER

A cooperative approach in mechanism design. ....... ....... .... ........ ..... .... ..... ...... ......... 241 P. CHEDMAIL, T. DAMA Y and B. Y ANNOU

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Study of complex tackles : lifting systems with pulleys and cables ........................ 249 A. BILLEREY, P. CLOZEL and D. CONSTANT

Application of a fuzzy logic ordering method to preliminary mechanism design.. 257 lC. FAUROUX, C. SANCHEZ, M. SARTOR and C. MARTINS

RVS : a robot visualization software package......................................................... 265 J. DARCOVITCH, l ANGELES, P. MONTAGNIER AND CHU-JEN WU

Chapter 5: ANALYSIS AND OPTIMIZATION OF MATERIAL FORMING PROCESSES ............................................................... 273

Clinchjoining modeling with the static explicit method and remeshing ................ 275 V. HAMEL, lM. ROELANDT, J.N. GACEL and F. SCHMIT

Theoretical and practical aspects in modeling of the metal powder compaction process .................................................................................... 283 A. GAKWAYA, H. CHTOUROU, andM. GUILLOT

Study and evaluation of different formulations ofthe optimization problem applied to the stamping process............................................................................... 291 l PA VIE, E. DI PASQUALE, S. BEN CHAABANE and V. BRAIBANT

Design optimization of metal forming processes .................................................... 299 O. GHOUATI and lC. GELIN

Modeling and blank optimum design ofthin car panels obtained by sheet metal forming ............................................................................................ 307 Y.Q. GUO, H. NACEUR, lL. BATOZ, C. KNOPF-LENOIR, O. BARLET,

F. MERCIER and S. BOUABDALAH

Shape and thickness optimization of an aeronautical structure manufactured using age creep forming process ...................................................... 315 lP. BOURDIN, J.P. BONNAFE, l DELMOTTE, E. GROSJEAN and lM. ROELANDT

Two component finite element model for the simulation of shaping of prepreg woven fabric .......................................................................................... 323 A. CHEROUAT, J.L. BILLOET and S. BELHOUS

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A sensitivity analysis for the spring back ofthe arched tubes................................. 331 J.c. DIENI, P. PATOU, H. SHAKOURZADEH and V. BRAIBANT

Chapter 6 : MODELING FOR CONTROL AND MEASUREMENT TOLERANCING AND ASSEMBLY IN MANUFACTURING .................................. 339

Influence ofthe Machine-Tool defects on the formation of the residual defects on a surface : application to tuming .................................... 341 A. GOUSKOV and S. TICHKIEWITCH

Certification offree-form machining: a comprehensive approach from CAD/CAM to measurement ........................................................................... 349 D. FEAUTRIER, F. THIEBAUT, G. TIMON and C. LARTIGUE

Nominal and actual geometry explicit declaration Application to dimensional inspection .................................................................... 357 C. CUBELES-VALADE and A. RlVIERE

Adaptative digitization of mechanical parts ............................................................ 365 F. BENNIS and F. DANIEL

Geometric tolerance transfer for manufacturing by an algebraic method .......... ..... 373 F. BENNIS, L. PINO and C. FORTIN

Modeling dispersions affecting pre-defined functional requirements ofmechanical assemblies usingjacobian transforms.............................................. 381 L. LAPERRIERE and PH. LAFOND

Toward a computer aided tolerancing system for parts and mechanisms .............. 389 E. BALLOT, F. THIEBAUT and P. BOURDET

Interactions between tolerancing and structural analysis views in design processes .................................................................................................. 397 S. SAMPER and M. GIORDANO

Fixturing effects on workpiece quality in milling ................................................... 405 A D'ACUNTO, 1. LEBRUN, P. MARTIN and M. GUEURY

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Chapter 7: OFF LINE PROGRAMMING AND OPTIMAL PARAMETERS FOR MACHINING, WELDING AND ROBOTICS .................................................. 413

Subassemblies detection with genetic algorithms ................................................... 415 P. DE LIT, E. FALKENAUER and A. DELCHAMBRE

Tool path correction on a numerically controlled machine-tool by characterisation of scattering in relation to type of machining ............................... 423 G. DES SEIN, J.M. REDONNET, P. LAGARRIGUE and W. RUBIO

A ring-shaped mechanical assembly line optimized by a genetic algorithm........... 431 F. FONTANILI, A. VINCENT, T. SORIANO and R. PONSONNET

Side milling of ruled surfaces-optimum tool radius determination and milling cutter positioning.................................................................................. 439 1M. REDONNET, G. DES SEIN, W. RUBIO AND P. LAGARRIGUE

Optimization of end-mill roughing operation sequence .......................................... 447 F. VILLENEUVE

A model for the optimization ofthe relation between product means and product 455 S. TASSEL, F. VILLENEUVE and O. LEGOFF

Optimal mill positioning in five axis machining on free form surfaces Application at roughing path of moulds.................................................................. 463 W. RUBIO, J.M. REDONNET, G. DESSEIN and P. LAGARRIGUE

A voiding the need for deburring by analyzing burr formation during product design.............................................................................................. 471 L. BLONDAZ, D. BRISSAUD and D. DORNFELD

Chapter 8: INTEGRATED DESIGN METHODOLOGY AND APPLICATIONS. DESIGN AND COMMUNICATIONS................................. 479

Engineering design: management of information and uncertainty......................... 481 C.A. MCMAHON

Towards a need satisfaction oriented computer aided design ................................. 489 F. LIMA YEM and B. Y ANNOU

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Aided design of brass musical instruments.............................. ............................... 497 lF. PETIOT and J. GILBERT

Environmentally-conscious design and materials selection .................................... 505 ULRIKE G.K. WEGST and M. F. ASHBY

Design knowledge representation for constrained-based design in CAD systems.. 513 C. LENGUIN and P.A. YVARS

CONCAD Bridging : Managing the integration oftechnical solutions in a modularized product concept ........................................................................... 521 M.W.LANGE

Mechanical models management in engineering design ......................................... 529 N. TROUSSIER, F. POURROY, M. TOLLENAERE and B. TREBUCQ

Proposal to control the systems design process Application to manufactured products .................................................................... 537 PH. GIRARD. B. EYNARD AND G. DOUMEINGTS

Integrated design of mechanical systems by a concurrent engineering approach ... 545 P. RA Y, M. NIGROWSKY, G. GOGU, C. DEMARQUILL Y and A. MALLON

Contribution to a multi-views, multi-representations design framework applied to a preliminary design phase ..................................................................... 553 MG-IT collective noun (Coordinator: J.C. LEON)

Proposal of a functional model oflogistics for spare parts preservation................. 561 N. BAUD, M. MEKHILEF and lC. BOCQUET

A generic model for know-how capitalization ........................................................ 569 J. LE CARDINAL

Web-based product information visualization through VRML code generation .... 577 YOONHOSEO

Collaborative design in education : the TAXIA project.......................................... 585 B. RAMOND

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Chapter 9: INTEGRATED MANUFACTURING METHODOLOGY AND APPLICATIONS ............................................................................. 593

A fast and reliable cost-estimation tool for hot-forged parts........................ ....... 595 M. BERLIOZ. PH. MARIN and S. TICHKIEWITCH

Cost-based ranking for manufacturing process selection ................................... 603 A. ESA WI and M. ASHBY

Analytical study ofmulti-agent oriented manufacturing design.......................... 611 v. PATRITI, K. SCHAFER, P. CHARPENTIER and P. MARTIN

Dynamic representation of a manufacturing process......................................... 619 B. ANSELMETTI and A. TOUMINE

Extensions of object formalism for representing the dynamics Application to the integration of viewpoints in the design of a production system 627 M. BIGAND, D. CORBEEL, D. NDIA YE and J.P. BOUREY

Multidimensional taguchi's model with dependent variables in quality system.... 635 C. TARCOLEA, G. DRAGOI, D. DRAGHICESCU and S. TICHKIEWITCH

An approach to integrate safety at the design stage ofnumerically controlled woodworking machines .......................................... 643 D. JOUFFROY, S. DEMOR, J. CICCOTELLI and P. MARTIN

Virtual manufacturing : set up of a cooperative work in manufacturing................ 651 PH. DEPINCE, H. THOMAS, B. FURET, Y. GRATON and N. RAFII

PREFACE

This volume contains the selected manuscripts of the papers presented at the Second IDMME Conference on "Integrated Design and Manufacturing in Mechanical Engineering", held in Compiegne, France, at the University of Technology of Compiegne, May 27-29, 1998.

The purpose of the Conference was to present and discuss topics dealing with the optimization of product design and manufacturing processes with particular attention to (1) the analysis and optimum design of mechanical parts and mechanisms (2) the modeling of forming processes (3) the development of computer aided manufacturing tools (4) the methodological aspects of integrated design and manufacturing in adapted technical and human environments.

The initiative of the conference and the organization thereof is mainly due to the efforts of the french PRIMECA group (Pool of Computer ResoUfces for Mechanics). The international Institution for Production Engineering Research (C.I.R.P.) was helpful to attract international participants.

The conference brought together three hundred and twenty worldwide participants. Hundred and thirty two papers were presented in oral or poster sessions and included in the proceedings in fOUf volumes given to the participants. FOUf invited lectures were presented:

1. Integrated design and manufacturing applied to aerospace structures by Didier Guedra-Degeorges from Aerospatiale, Suresnes, France

2. Engineering Design: management of information and uncertainty by Professor Chris Mac-Mahon, University ofBristol, UK

3. Adaptative topology and shape optimization by Professor Ekkehard Ramm, University of Stuttgart, Germany

4. The next-generation manufacturing research: a North-American perspective by Professor Clement Fortin, Ecole Polytechnique, Montreal, Canada

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This book contains eighty papers selected by the International Scientific Committee

and the PRIMECA Scientific committee :

Chairman: Co-chairmen:

J.L. Batoz (France) P. Chedmail (France) D. Dornfeld (USA)

G. Cognet (France) C. Fortin (Canada)

International Scientific Members:

1. Angeles (Canada) P. Bettess (UK) J.C. Bocquet (France) P. Bourdet (France) A. Clement (France) Y. Corvez (France)

H. Hagen H. (Germany) H.I.J. KaIs (The Netherlands) F. Kimura (Japan) T. Kjellberg (Sweden) F. Le MaHre (France) R. Soenen (France)

Primeca Scientific Members:

J. C. Bocquet J.c. (EC Paris) C. Bonthoux C. (IFMA) J.L. Caenen (Mines de Douai) J.M. Castelain (ENSIMEV) P. Clozel (EC Lyon)

G. Degallaix (EC LilIe) H. Gachon (ENSAM) J. Guillot (INSA Toulouse) P. Orsero (UTC) J. P. Pelle (ENS Cachan)

S.H. Such (Korea) S. Tichkiewitch (France) M. Touratier (France) H. Van Brussel (Belgium) M. Veron (France)

B. Peseux (EC Nantes) D. Play (INSA Lyon) G. Ris G. (AlP Nancy) M. Tollenaere (lNPG)

The above specialists cover a large spectrum in computer science applied to analysis, design and fabrication in mechanical engineering problems.

The third IDMME Conference will take place in Montreal, Quebec, Canada on May 17-19,2000.

The editors, the scientific and organizing committees hope that they contributed to the development of the challenging research domain of lntegrated Design and Manufacturing in Mechanical Engineering.

The editors 1.L. Batoz, P. Chedmail, G. Cognet, C. Fortin

ACKOWLEDGEMENTS

The Second IDMME Conference held in Compiegne in may 1998 received the scientific support of the M.E.S.R (French Ministry of Higher Education and Research), the C.N.R.S. agency (French National Agency for Scientific Research), the C.I.R.P. (International Institution for Production Engineering Research), the AU.M. (French University Association of Mechanics), the C.S.M.A (French Computational Structural Mechanics Association).

The M.E.S.R., the A.U.M. and the C.S.M.A organizations provided financial support for the Conference and for the edition of this book.

All members of the organizing committee contributed to a successful conference. These members belong to the Department of Mechanical Engineering Systems Department (Laboratoire LG2MS, University of Technology of Compiegne), Laboratoire de Mecanique de Lille), Laboratoire d'Automatique et de Mecanique Industrielles et Humaines (E.N.S.I.M.E.V., Valenciennes). P. Orsero (U.T.C) was chairman of the Organizing Committee and G. Degallaix (E.c.L.) and D. Coutellier (E.N.S.I.M.E.V.) acted as co-chairmen.

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INTRODUCTION

This book is devoted to the optimization oj product design and manujacturing. It contains selected and carefully composed articles based on presentations given at the IDMME conference held in Compiegne University of Technology, France in 1998. Their authors are all involved in cutting-edge research in their respective fields of specialization.

The integration of manufacturing constraints and their optimization in the design process is becoming more and more widespread in the development of mechanical products or systems. There is a clear industrial need for these kinds of methodologies. This class of problems belongs to the problematic of Concurrent Engineering which is the object of many academic and industrial projects in Europe (through the ESPRIT and BRlTE-EURAM projects particularly) and all over the world.

Important - but still unsolved - problems are related to the definition of design processes, the choice of optimal manufacturing processes and their integration through coherent methodologies in adapted environments. In the same time, different aspects of the problem have to be explored :

the representation of the products and their properties, the modeling of the processes, the enhancement of the elementary design activities supported by classical CAD­CAM systems.

Three main topics are addressed in this book: 1. Analysis and optimization oj mechanical parts and products. In the first chapter,

examples dealing with structural analysis of mechanical parts describe the complexity of the activity of concurrent engineering. These examples demonstrate the actual possibilities to simultaneously take into account thermal and mechanical constraints (p. 11), very complex phenomena which are associated to the crash of vehicles (pp. 19 and 51) or to gearboxes functioning (p. 59). The second chapter is devoted to some aspects of the optimal design of mechanical structures. Apart from the classical shape optimization techniques (pp. 101 and 109), it appears clearly that topological optimization techniques (pp. 117 and 133) are an alternative for the research of new solutions. In the same time, global approaches (pp. 85,93 and 125) are a potential solution when there exist many local minima of the objective function. The third chapter is dedicated to the problem of the integration of the finite element sol vers within CAD systems. A key point in this domain is to get a fluent "go-back" process between the numerical mockup of the product and the finite element model (pp. 151, 159 and 167). This goes through the development of efficient automatic meshing algorithms (pp. 143 and 191), new geometric tools for representing complex objects (pp. 167, 183, 199 and 207). The kinematics models are studied in chapter 4 about modeling and synthesis of mechanisms. Out of the classical problem of the analysis of mechanisms (pp. 217 and 265), it becomes

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clear that mechanisms synthesis - from a dimensional (pp. 225, 233 and 249) or a topological point of view (pp. 241 and 257) - is a today challenge for industrial purpose. This appears after a long period of academic researches which led to practicallimitations due to computers limitations.

2. Analysis and optimizationfor production and manufacturing systems. In this topic, the authors study the complementary aspect of the design process, i.e. the manufacturing and production processes (machining, stamping, c1inching, age creep forming, ... ). Chapter 5 is related to the optimization of forming processes. Taking into account the complex mechanical phenomena (pp. 275, 283, 323 and 331), it becomes possible to develop some optimization techniques applied to these processes (pp. 299, 307 and 315). The object of chapter 6 is the modeling for control and measurement (pp. 341, 349, 365, 405), and tolerancing (pp. 357, 373, 381 and 389). This last subject clearly interacts with functional and structural views in the design process (p. 397). In chapter 7, design and manufacturing integration goes through off line programming (pp. 415, 431, 455 and 471) and the optimal definition of parameters for machining (pp. 423, 439, 447 and 465).

3. Methodological aspects of integrated design and manufacturing. The two above topics are clearly complementary. Moreover they have to be integrated as much as possible. The new methodologies based on the management of fuzzy information (pp. 481) and know-how (p. 569), multi-model (pp. 521, 529, 553 and 569) and constrained-based approaches (p. 513) are presented in chapter 8. Presentations on design with new communication tools (p. 577) and new methodologies (pp. 489, 545 and 561) complete this chapter. Chapter 9 is related to computer aided manufacturing : cost criteria are central in this domain (pp. 595 and 603). Otherwise, modeling of the process becomes possible with multi-agent approach (p. 611). It may include dynamical aspects of the process (pp. 619 and 627).

Some training applications are finally presented in the domains of collaborative design or manufacturing (pp. 585 and 651).

By the end, apart from giving a thorough theoretical background, a very important theme is the relation between research and industrial applications.

We hope that this book will be of interest for engineers, researchers and Ph.D. students who are involved in the optimization of design and manufacturing processes. It will be amine of examples and ideas, and we wish that it will contribute to the improvement and the development of concurrent engineering.

The editors J.L. Batoz, P. Chedmail, G. Cognet, C. Fortin