A Quality Prediction Framework for Multistage Machining Processes Driven by an Engineering Model and Variation Propagation Model

[+] Author and Article Information
Jianming Li, S. Jack Hu, Yoram Koren

NSF Engineering Research Center for Reconfigurable Manufacturing Systems, The University of Michigan, Ann Arbor, MI 48109

Theodor Freiheit

Department of Mechanical and Manufacturing Engineering, University of Calgary, Calgary, Alberta, T2N1N4, Canada

J. Manuf. Sci. Eng 129(6), 1088-1100 (Apr 09, 2007) (13 pages) doi:10.1115/1.2752520 History: Received May 17, 2005; Revised April 09, 2007

This paper proposes a comprehensive quality prediction framework for multistage machining processes, connecting engineering design with the activities of quality modeling, variation propagation modeling and calculation, dimensional variation evaluation, dimensional variation analysis, and quality feedback. Presented is an integrated information model utilizing a hybrid (feature/point-based) dimensional accuracy and variation quality modeling approach that incorporates Monte Carlo simulation, variation propagation, and regression modeling algorithms. Two important variations (kinematic and static) for the workpiece, machine tool, fixture, and machining processes are considered. The objective of the framework is to support the development of a quality prediction and analysis software tool that is efficient in predicting part dimensional quality in a multistage machining system (serial, parallel, or hybrid) from station level to system level.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 8

Validation of simulation results

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Figure 9

Bearing carrier cover plate

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Figure 10

Machining process options and layout

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Figure 11

Histograms of top surface flatness for three process options

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Figure 3

Example of face graphs

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Figure 4

Entities and their relationship for quality information model

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Figure 5

Multistage variation propagation modeling

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Figure 6

Workpiece variation calculation

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Figure 7

Quality modeling module interface

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Figure 1

Framework for quality prediction and analysis

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Figure 2

Interfaces between CAD/CAPP/CAM/CAE and quality modeling



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