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PROCEEDINGS OF THE
THIRTIETH INTERNATIONAL MATADOR
CONFERENCE
held in Manchester 31st March - 1st April 1993
Edited by
A. K. KOCHHAR Lucas Professor of Manufacturing Systems Engineering
Manufacturing Division Department of Mechanical Engineering
UMIST
DEPARTMENT OF MECHANICAL ENGINEERING UNIVERSITY OF MANCHESTER INSTITUTE OF SCIENCE AND TECHNOLOGY
in association with
MACMILLAN EDUCATION
!50th YEAR
M MACMILLAN
© Department of Mechanical Engineering University of Manchester Institute of Science and Technology
1993 Softcover reprint of the hardcover 1st edition
1993 978-0-333-59648-7
All rights reserved. No reproduction, copy or transmission of this publication may be made without written permission.
No paragraph of this publication may be reproduced, copied or transmitted save with written permission or in accordance with the provisions of the Copyright, Designs and Patents Act1988, or under the terms of any licence permitting limited copying issued by the Copyright Licensing Agency, 90 Tottenham Court Road, London W1P 9HE.
Any person who does any unauthorised act in relation to this publication may be liable to criminal prosecution and civil claims for damages.
First published 1993 by the Department of Mechanical Engineering
UMIST P.O. Box 88, Manchester M60 1 QD
in association with THE MACMILLAN PRESS LTD
Houndmills, Basingstoke, Hampshire RG21 2XS and London
Companies and representatives throughout the world
ISBN 978-1-349-13257-7 ISBN 978-1-349-13255-3 (eBook) DO 10.1007/978-1-349-13255-3
A catalogue record for this book is available from the British Library
I
THIRTIETH INTERNATIONAL MATADOR
CONFERENCE 31st March - 1st April 1993
ORGANIZING AND REVIEWING COMMITTEE
Professor A. K. Kochhar (Chairman) Dr. J. Atkinson Dr. G. Barrow Dr. P. Brunn
Dr. M. Burdekin Dr. N. R. Chitkara
Dr. W. Graham Dr. R. G. Hannam
Dr. S. Hinduja Mr. R. Kirk
CONFERENCE SECRETARIES
Mrs. S. Mellor Ms. F. Sharrock
CONTENTS
KEYNOTE ADDRESS: Competitiveness in Manufacturing -Putting all the elements together J. PARNABY, CBE
MANUFACTURING SYSTEMS Applying the lessons learned from 146 manufacture to the next generation of regional aircraft
N. MASOM 5
Total manufacturing systems: The operational reality B. TROUGHT 15
A systematic basis to manufacturing G.G. ROGERS 21
Strategic planning of information systems H. CATHER and S. KARABABAS 27
Organisational aspects of information systems design L.E. DAVIS, J.P. DUBERLEY, S.A. BLENKINSOP and N.D. BURNS 35
Effective tool maintenance information management C. O'BRIEN, H. SCHAFER and J.K. BRYANT 43
Repetitive manufacturing management information systems A. DeTONI and R. PANIZZOLO 49
An effective computer based assembly line balancing method X. MA and H.W. LIU 57
TQM2: A meta-methodology for revitalizing flagging quality initiatives S. SMITH, D. TRANFIELD, S. WHITTLE and M. FOSTER 65
Continous quality improvement in short run manufacture L.R. CARTER and C. BUTLER 75
Total productive maintenance: Quality and responsibility through worker involvement A.A. SWINTON and A.J. DAY 83
Set up and maintenance issues arising from the implementation of cellular manufacture in an injection moulding factory
J.S. MORTON, P.J. ROSAIR, M.J. HOLGATE and P.G. MAROPOULOS 95
A study of feedscrew container handling systems on liquid packaging lines with a view to optimisation C. LEE and H.G. PATEL 103
vii
METAL CUTTING AND GRINDING The machining of TiA 1-based intermetallics
H. ZANG, M.L.H. WISE and D.K. ASPINWALL Ill
Some ultrasonic effects in machining materials encountered in the offshore industries D. CLIFTON, Y. IMAI andJ.A. McGEOUGH 119
Conventional machining of an aluminium based SiC reinforced metal matrix composite (MMC) alloy R.T. COELHO, S. YAMADA, T. le ROUX, D.K. ASPINWALL and M.L.H. WISE 125
Surface roughness model for end milling metal matrix composite (A1/SiC) M. ALA UDDIN, M.A. EL BARADIE and M.S.J. HASHMI 135
CAE applied to twist drills R. LEADBETTER and M. MCCOLL 143
Strategy of machinability of alluminium alloys for free cutting J. KOPAC, M. SOKOVIC,A. SMOLEJ,A. GORCENKO and V. DRAGOJEVIC 151
On line tool life prediction for tool replacement strategy in FMS workstation S. NOTO LA DIEGA, A. PASSANNANTI and Z. TANG 157
Recognition of chip forms by means of dynamic force spectrum analysis W. GRZESIK 163
A review of polycrystalline cubic boron nitride cutting tool developments and application A.M. ABRAO, D.K. ASPINWALL and M.L.H. WISE 169
The failure of metal cutting tools at tool/work disengagement Z.Q. QIAN, J.F.L. CHAN and P.M. BRAIDEN 181
The real contact length in grinding based on depth of cut and contact deflections W.B. ROWE, QI HONGSHENG, M.N. MORGAN and ZHENG HUANWEN 187
The identification of dressing strategies for optimal grinding wheel performance W.B. ROWE, XUN CHEN and M.N. MORGAN 195
METAL FORMING Development of roll-less forming process for ultra-thin wall welded pipe production
T. NAKAKO, A. TAKEZOE and S. INOUE 205
An automatic speed programme generation for SRM G. PELLEGRINI, C. GIARDINI and A. BUGINI 211
Modelling of deep-drawing of complex shaped components using slip-line methods F. BOOR 217
Cold extrusion of flanges on cylindrical hollows B. LENGYEL, S.A. SHAHMORADI and I.A. CHAUDHRY 227
Computer aided metal flow simulation and die design optimization for axisymmetric forging process F. DIKO and M.S.J. HASHMI 235
Electric discharge machining of an aluminium alloy silicon carbide reinforced metal matrix composite T. le ROUX, M.L.H. WISE and D.K. ASPINWALL 247
Vlll
The investigations of electrochemical machining process when using non profiled electrode A. RUSZAJ, M. ZYBURA-SKRABALAK and M. CHUCHRO
Experimental study of the printing of solder paste using the metal blade squeegee system I. ISMAIL, S.H. MANNAN, N.N. EKERE and E.K. LO
Variable composition laser cladding of copper alloys M. ELLIS, D.C. XAIO, W.M. STEEN and C. LEE
MANUFACTURING EDUCATION A hypermedia-based tutoring system for education in mechanical engineering
K. CHENG and W.B. ROWE
Benefits of joint roles to manufacturing education C.J. BACKHOUSE and N.D. BURNS
The application of advanced manufacturing technology in New Zealand R.H.A. SEIDEL, J.D. TEDFORD, M.H. NORTON and I.M.P. SLY
A proposal for a postgraduate CAD/CAM course I.I. ESAT
EXPERT SYSTEMS Increasing the acceptance of knowledge-based systems
R.P. MAIN and K. OLDHAM
Lot production: A rule-based expert system approach A. DE TONI, G. NASSIMBENI and S. TONCHIA
Industrial applications of model-based approaches to fault diagnosis N.F. DOHERTY and A.K. KOCHHAR
Practical development of knowledge-based systems in manufacturing K. OLDHAM, R.M. HATHER, J. HALTON and A.K. KOCHHAR
Fuzzy selection of concurrent engineering implementation tatics F. LETTICE, A. MATIN and S. EVANS
NEURAL NETWORKS Control of multisensor systems by neural networks
Z. NAGY and T. SZALAY
Neural network techniques for metal forming design A. BARCELLONA
Development of an intelligent robotic cell C. LEE and M-H. YU
A transputer based neural network development system for industrial control applications J.P. RUIZ-MIGUELA and P.J. BRUNN
Intelligent scheduling of sequence dependent set-up times using neural network T.J. SUH and I.I. ESAT
ix
255
263
267
277
285
291
295
303
315
323
331
345
355
361
367
375
381
MATERIALS MANAGEMENT System dynamic models for improving the design and operations of supply chains
D.R. TOWILL and M.M. NAIM
Performance and organisation of very small firms in the supply chain A. DE TONI, M. MUFFATTO, G. NASSIMBENI and A. VINELLI
Integrated materials management-redefining the value chain P. HINES
Use of statistical techniques in the dynamic modelling of an industrial supply chain M. GRIFFITHS, K. HAFEEZ and M.M. NAIM
MANUFACTURING SYSTEMS MODELLING Performance modelling in CIM
S.I. MARRIOTT, V.C. MACHADO, V.R. NEWMAN and P.J. SACKETT
An evaluation of Siman for simulating FMS tool management systems N.T. WANG and R.G. HANNAM
The design of cellular manufacturing systems and whole business simulation P.A. LEWIS and D.M. LOVE
On the modelling and simulation of flexible assembly systems using coloured petri-net P.P. CICCIOLA, R. GROPPETTI and M. LA CAVA
Towards a standard in FORCAST A.N. GODWIN AND D. SAUNDERS
DESIGN Performance Improvement of slowly moving fluid power drives using pulse-width-modulation
S.M.HARB
Establishing a rule base for the computer aided design of tooling for the multi-stage pressing of cylindrical cups
B. FOGG
Finite element analysis of press tools K.W. DUNLOP and U.P. SINGH
A photo-elastic and strain gauge technique of stress analysis in rod-drawing M.T. HILLERY and V.J. McCABE
Computer aided analysis of high frequency induction heating process of steel J. DOPKIN, K. SADEGHIPOUR and K. LI
Capabilities of a new and generalized approach for creating solid models from two-dimensional drawings
K.S. TAM and J. ATKINSON
CAD modelling of sculptured workpieces from physical models WEIYIN MA, J.P. KRUTH and P. VANHERCK
Representation and manipulation of fastener knowledge G. ZHONG and M. DOONER
X
389
397
405
413
423
429
435
443
451
461
469
477
485
493
501
511
519
COMPUTER AIDED PROCESS PLANNING CCSPLAN: A generative process planning system
ZHENGXU ZHAO and R.W. BAINES 527
A knowledge-based representation and a decision-based approach for advanced manufacturing systems A. CHEP and B. ANSELMETTI 535
Disassembly process planning M. SIMON and T. DOWIE 543
Information mapping between a feature-based design system and an integrated process planning system
J.X. GAO and K. CASE 551
Computer integrated design and manufacture of complex geometries in concurrent engineering B. GOPALAKRISHNAN and V. PANDIARAJAN 559
Integration of constraint and solid modellers A.J. MEDLAND, G. MULLINEUX and A.H. RENTOUL 565
Representation of surfaces in 3D wireframe models ZHENGXU ZHAO, G.N. BLOUNT, R.M. JONES and R.W. BAINES 573
Symbolic representation of geometrical data of extrusion dies S.G. AHMED, J.M. SHARP and A.M. DORE 581
Representing geometrical and technological data in feature-based part models S.R.K. JASTHI, A.V.S.R.K. PRASAD, V. ARORA, P.N. RAO, U.R.K. RAO and N.K. TEWARI 589
Modelling and optimisation of turning operations R.M.D. MESQUITA and E.P. HENRIQUES 599
ROBOTS Prototype of perceptive glove with feedback force for telerobotics in flexible manufacturing manipulation
A. ROVETTA, X. WEN, A. TOGNO, S. MILANESI and E. GENTILI
A system for on-line performance monitoring of industrial robots A.G. STARR, I.J. KENNEDY and R.J. WYNNE
Flexible vision-assisted handling system for the packaging of food products T. BONFIELD, A.M. DORE and J.M. SHARP
Microprocessor controlled pneuma-hydraulic positioning system for a robotic manipulator S.M. DE ALMEIDA and T. ROACHE
A structured approach to vision monitoring I.M.P. SLY
XI
611
617
627
637
645
MANUFACTURING METROLOGY Assessing fundamental geometric form from measured coordinate data
M.G. COX and P.M. HARRIS
Position calibration software for the form assessment of complex workpieces A.B. FORBES
Measurement of the accuracy of a Puma 560 industrial robot D.A. HORNSHAWandA.J. DAY
Criteria for possibilities of industrial robot application to measurement and inspection operations L.NAWARA
Evaluation of polished silicon wafers' micro-roughness by atomic force microscope Y. SAMITSU
Contour assessment of CNC machine tools M. GULL and N. GARNER
Automatic position and orientation correction for automated assembly robots H.J. REA, R. RAESIDE and J. LEWIS
Digital filtering in roughness measurements A.A. BRUZZONE and P.M. LONARDO
SCHEDULING Scheduling for success in process industries
B.W. DINES
A real-time scheduling method using hierarchical decentralized decision makers for flexible manufacturing systems
K. MORI, M. TSUKIYAMA and T. FUKUDA
Real-time routing selection in flexible manufacturing systems M.P. FANTI, E. LO VALVO, M. PIACENTINI and G. PISCITELLI
Flow-shop scheduling: Effect of various priority rules on minimizing multiple criteria MUJANAH, EZAT AGHA and M. EL BARADIE
xii
655
663
671
681
685
691
699
705
713
719
727
733
Foreword
by Conference Chairman
It gives me great pleasure to introduce to you the proceedings of the 30th International MATADOR Conference. The Conference has attracted papers from thirteen countries other than the United Kingdom and hence fully justifies the word 'International.'
The MATADOR Conference was established in 1959, which makes it one of the longest established Conferences in the field of manufacturing in the world. It covers a wide area of interest to researchers and industrialists working in a range of manufacturing industries. The topics covered by the successive Conferences have always reflected the important developments in research in the whole of manufacturing. It is therefore natural that while maintaining a strong technological base, this Conference has attracted papers in a number of related areas. For example, this year we have a large number of papers on expert systems and neural networks. This reflects the increasing growth of research and development in the areas of expert systems and neural networks applied to manufacturing. Another new theme at this conference is manufacturing education which is of considerable interest to academics and industrialists alike.
As for the future, intelligent automation is providing for the simultaneous achievement of considerable flexibility, precision and productivity. Manufacturing, as a whole, is moving from art to science. Machines, and the associated control systems increasingly incorporate very considerable intelligence. This trend will accelerate over the years to come. It will become increasingly necessary to bring together, in a creative manner, the human intelligence and the machine intelligence, for solving the complex manufacturing problems. Research work in these areas will be very challenging since it will be necessary to devise new paradigms and structures which recognise the increasing amount of intelligence built into machines. This will prove a very considerable challenge for the researchers as well as practitioners in industry.
I hope that the readers will find the papers interesting and stimulating.
PROFESSOR A.K. KOCHHAR
xiii