A prototype constraint-based system for the automation and optimization of machining processes

Abstract

This paper presents an intelligent design system that enables designers to consider at the early stages of the design process all issues associated with the product life cycle. The evaluation and optimization of machining processes are among the most important aspects of these issues, requiring the involvement of various types of information from the different aspects of the product life cycle. The representation of this information in efficient format is very important for carrying out different design tasks. In order effectively to manage information exchange within different design and manufacturing domains, it is necessary to provide an efficient and timely communication network system. Therefore, various critical tasks such as overall coordination, control, consistency and data integrity have to be considered in order to avoid costly design iterations. This research article has focused on the development of a prototype system for machining process optimization.

The system uses a combination of both mathematical methods and constraint programming techniques and provides designers with the evaluation and optimization of feasible machining processes in a consistent manner at the early stages of the design process. As a result, unexpected and costly design iterations, which result in wastage of a great amount of engineering time and effort, and in a longer lead time, can be avoided.

The development process has passed through four major stages. Firstly, an intelligent constraint- based design system for concurrent product and process design, including a machining process optimization module, has been developed. Secondly, the product features, processes, cost, time and requirements have been represented in the format of constraints, frames, objects and production rules in order to be utilized to accomplish different design tasks. Thirdly, rules for the selection and optimization of feasible processes for complex features have been written, and finally, an information management system, with a conflict resolution mechanism, has been developed to achieve consistency in information exchange and decision-making activities between the different design areas.

Keywords

concurrent engineering process optimization cost estimation constraints knowledge- based systems feature-based design object-oriented programming design consistency conflict resolution

References

Ou-Yang

Lin

T. S.

Developing an integrated frame work for feature-based early manufacturing cost estimisation. Int. J. Advd Mfg Technol., 1997, 13(9), 618–629.

Huthwaite

Manufacturing competitiveness and quality by design; ICD/FOCUS method, In Proceedings of Fourth International Conference on Product Design for Manufacture and Assembly, 1989.

Abdalla

H. S.

Concurrent engineering for global manufacturing. Int. J. Prod. Econ., 1998, 1–10.

O'Grady

Young

R. E.

Greef

Smith

An advice system for concurrent engineering. Int. J. Comput. Integrated Mfg, 1991, 4(2), 63–70.

Noble

J. S.

An approach to overall design consistency in concurrent engineering. Int. J. Flexible Automn and Integrated Mfg, 1993, 1(1), 25–36.

Karacali

Bell

Concurrent design expert application with CAE driven information models. In Proceedings of 31st International MATADOR Conference, 1995, pp. 479–484.

Balasubramanian

Norrie

D. H.

A multi-agent architecture for concurrent design, process planning, routing, and scheduling. Concurrent Engng: Res. and Applic., 1996, 4(1), 7–15.

Lander

S. E.

Corkill

D. D.

Designing integrated engineering environments: Blackboard-based integration of design and analysis tools. Concurrent Engng: Res. and Applic., 1996, 4(1), 59–70.

Dewhurst

Boothroyd

Early cost estimating in product design. J. Mfg Syst., 1998, 7(3), 183–191.

10.

Thurston

Carnahan

Intelligent evaluation of designs for manufacturing cost. In Concurrent Engineering: Automation, Tools, and Techniques (Ed. Kusiak

), 1993, pp. 401–443 (John Wiley, New York).

11.

Taiber

J. G.

Development of an optimisation method for determination of process sequences considering prismatic workpieces. Trans. ASME, Comput. in Engng, 1994, 1, 271–280.

12.

Tappeta

V. R.

Ranaud

E. J.

A comparison of equality constraints formulation for concurrent design optimisation. Concurrent Engng: Res. and Applic., 1997, 5(5), 253–261.

13.

Downlatshahi

Ashok

M. S.

Design optimisation in concurrent engineering: A team approach. Concurrent Engng: Res. and Applic., 1997, 5(5), 145–154.

14.

Gayretli

Abdalla

An expert system for manufacturing process optimisation. In Proceedings of TMCE ′98, Manchester, 1998.

15.

Fen

C. J.

Kusiak

Huang

Cost evaluation in design with form features. Comput.-Aided Des., 1996, 28(11), 879–885.

16.

Shaikh

M. A.

Hansotia

B. J.

Minimisation of drilling cost: A closed-form solution. Comput. and Ind. Engng, 1992, 23(1-4), 443–446.

17.

Das

Gupta

S. K.

Nau

D. S.

Reducing set-up cost by automated generation of redesign suggestions. Trans. ASME, Comput. in Engng, 1994, 1, 159–170.

18.

Das

Gupta

S. K.

Nau

D. S.

Estimation of set-up time for machined parts: Accounting for work-holding constraints using a vice. In Proceedings of the Computers in Engineering Conference and the Engineering Database Symposium, 1995, pp. 619–631 (American Society of Mechanical Engineers, New York).

19.

Luong

L. H. S.

Spedding

An integrated system for process planning and cost estimation in hole making. Int. J. Advd Mfg Technol., 1995, 10, 411–415.

20.

Pham

D. T.

Gologlu

Machining set-up planning based on evaluation of feature relations and fixturing constraints. In Application of Artificial Intelligence in Engineering XII (Eds Adey

R.A.

Rzevski

Teti

), 1997, pp. 35–38 (Computational Mechanics Publications, Southampton, Boston).

21.

Lee

I. B. H.

Lim

B. S.

Nee

A. Y. C.

IKOOPS: An intelligent knowledge-base object-oriented process planning system for the manufacture of progressive dies. Expert Syst., 1991, 8(1), 19–31.

22.

Abdalla

H. S.

Knight

An expert system for concurrent product and process design of mechanical parts. Proc. Instn Mech. Engrs, Part B, Journal of Engineering Manufacture, 1994, 208(B3), 167–172.

23.

Hashemian

A constraint-based system for product design. Concurrent Engng: Res. and Applic., 1995, 3(3), 177–185.

24.

Sun Common Lisp 4.0 Object System Guide, 1990.

25.

Machining Data Handbook, 3rd edition, 1980, Vols 1–2 (Metcut Research Associations Inc.).

26.

Ostwald

P. F.

AM Cost Estimator, 4th edition, 1988 (Penton Publishing).

27.

Chang

T. C.

Wysk

R. A.

An Introduction to Automated Process Planning System, 1985 (Prentice-Hall, Englewood Cliffs, New Jersey).

28.

Bralla

J. G.

Handbook of Product Design for Manufacturing, 1986 (McGraw-Hill, New York).

29.

Choi

H. S.

Park

K. H.

Shop-floor scheduling at shipbuilding yards using the multiple intelligent agent system. J. Intelligent Mfg, 1997, 8(6), 505–515.

30.

Berrais

Knowledge-based expert systems: User interface implications. In Advances in Computational Structure Technology, 1996, pp. 185–195 (Civil-Comp Press, Edinburgh).

31.

Chang

T. C.

Expert Process Planning for Manufacturing, 1990 (Addison-Wesley).