Search results for: Automotive part manufacturing measurement

Authors: Peter Kostal, Karol Velisek

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Flexible manufacturing system is a system that is able to respond to changed conditions. In general, this flexibility is divided into two key categories and several subcategories. The first category is the so called machine flexibility which enables to make various products by the given machinery. The second category is routing flexibility enabling to execute the same operation by various machines. Flexible manufacturing systems usually consist of three main parts: CNC machine tools, transport system and control system. A higher level of flexible manufacturing systems is represented by the so called intelligent manufacturing systems.

Keywords: drawing-free manufacturing, flexible manufacturing system, industrial robot, material flow.

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Authors: J. Ruso, M. Krsmanovic, A. Trajkovic, Z. Rakicevic

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Since the late 1970s, quality management has become an important tool for achieving a high quality of public e-administration services in many countries. Very important part of quality management in e-administration is measurement of quality indicators related to this sector. Therefore, this paper gives a description of e-administration, including statistics about it and other examples from many countries worldwide, as well as the explanation of quality management in public e-administration. The paper also gives a list and description of quality indicators relevant to e-administration, as part of quality management within the e-administration. Through a literature review and best practices, the paper aims to analyze quality indicators measurement and other parts of good quality management when it comes to the public e-administration and consequently to show the usefulness of quality management in public e-administration in order to provide services of high quality.

Keywords: e-Administration, quality indicators, quality management.

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Authors: Reihaneh Montazeri Shatouri, Rosmini Omar, Kunio Igusa

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Although automotive industry has brought different beneficiaries to human life, it is being pointed out as one of the major cause of global air pollution which resulted in climate change, smog, green house gases (GHGs), and human diseases by many reasons. Since auto industry is one of the largest consumers of fossil fuels, the realization of green innovations is becoming a crucial choice to meet the challenges towards sustainable development. Recently, many auto manufacturers have embarked on green technology initiatives to gain a competitive advantage in the global market; however, innovative manufacturing systems and technologies can enhance operational performance only if the human resource management is in place to elicit the motivation of the employees and develop their organizational expertise. No organization can perform at peak levels unless each employee is committed to the company goals and works as an effective team member. Strategic human resource practices are the primary means by which firms can shape the skills, attitudes, and behavior of individuals to align with the business strategic objectives. This study investigates on the comprehensive approach of multiple advanced technology innovations and human resource management at Toyota Motor Corporation as the market leader of full hybrid technology in the automotive industry. Then, HRM framework of the company is described and three sets of human resource practices that support the innovation-oriented HR system, presented. Finally, a conceptual framework for innovativeness in green technology in automotive industry by applying a deliberate strategic HR management system and knowledge management with the intervening factors of organizational culture, knowledge application and knowledge sharing is proposed.

Keywords: Automotive Industry, Green Technology, Innovation, Strategic Human Resource Management

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Authors: M. Rahou, A. Cheikh, F. Sebaa

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Manufacturing tolerancing is intended to determine the intermediate geometrical and dimensional states of the part during its manufacturing process. These manufacturing dimensions also serve to satisfy not only the functional requirements given in the definition drawing, but also the manufacturing constraints, for example geometrical defects of the machine, vibration and the wear of the cutting tool. In this paper, an experimental study on the influence of the wear of the cutting tool (systematic dispersions) is explored. This study was carried out on three stages .The first stage allows machining without elimination of dispersions (random, systematic) so the tolerances of manufacture according to total dispersions. In the second stage, the results of the first stage are filtered in such way to obtain the tolerances according to random dispersions. Finally, from the two previous stages, the systematic dispersions are generated. The objective of this study is to model by the least squares method the error of manufacture based on systematic dispersion. Finally, an approach of optimization of the manufacturing tolerances was developed for machining on a CNC machine tool

Keywords: Dispersions, Compensation, modeling, manufacturing Tolerance, machine tool.

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Authors: A. Peniak, J. Makarovič, P. Rafajdus, P. Dúbravka

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The purpose of this work is to optimize a Switched Reluctance Motor (SRM) for an automotive application, specifically for a fully electric car. A new optimization approach is proposed. This unique approach transforms automotive customer requirements into an optimization problem, based on sound knowledge of a SRM theory. The approach combines an analytical and a finite element analysis of the motor to quantify static nonlinear and dynamic performance parameters, as phase currents and motor torque maps, an output power and power losses in order to find the optimal motor as close to the reality as possible, within reasonable time. The new approach yields the optimal motor which is competitive with other types of already proposed motors for automotive applications. This distinctive approach can also be used to optimize other types of electrical motors, when parts specifically related to the SRM are adjusted accordingly.

Keywords: Automotive, drive system, electric car, finite element method, hybrid car, optimization, switched reluctance motor.

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Authors: Kati Kõrbe Kaare, Kristjan Kuhi, Ott Koppel

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Transportation authorities need to provide the services and facilities that are critical to every country-s well-being and development. Management of the road network is becoming increasingly challenging as demands increase and resources are limited. Public sector institutions are integrating performance information into budgeting, managing and reporting via implementing performance measurement systems. In the face of growing challenges, performance measurement of road networks is attracting growing interest in many countries. The large scale of public investments makes the maintenance and development of road networks an area where such systems are an important assessment tool. Transportation agencies have been using performance measurement and modeling as part of pavement and bridge management systems. Recently the focus has been on extending the process to applications in road construction and maintenance systems, operations and safety programs, and administrative structures and procedures. To eliminate failure and dysfunctional consequences the importance of obtaining objective data and implementing evaluation instrument where necessary is presented in this paper

Keywords: Key performance indicators, performance measurement system, evaluation, system architecture.

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Authors: Basavaraj Vadavadagi, Satishkumar Shekhawat

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Interstitial free steels possess better formability and have many applications in automotive industries. Forming limit diagrams (FLDs) indicate the formability of materials which can be determined by experimental and finite element (FE) simulations. FLDs were determined experimentally by LDH test, utilizing optical strain measurement system for measuring the strains in different width specimens and by FE simulations in Interstitial Free (IF) and Interstitial Free High Strength (IFHS) steels. In this study, the experimental and FE simulated FLDs are compared and also the stress based FLDs were investigated.

Keywords: Forming limit diagram, Limiting Dome Height, optical strain measurement, interstitial

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Authors: Phichak Phutrakhul

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The purposes of this research were to study concepts and strategies of human resource development in the automotive manufacturers and to articulate the proposals against the government about the human resource development for automotive industry. In the present study, qualitative study was an in-depth interview in which the qualitative data were collected from the executive or the executive of human resource division from five automotive companies - Toyota Motor (Thailand) Co., Ltd., Nissan Motor (Thailand) Co., Ltd., Mitsubishi Motors (Thailand) Co., Ltd., Honda Automobile (Thailand) Co., Ltd., and Suzuki Motor (Thailand) Co., Ltd. Qualitative data analysis was performed by using inter-coder agreement technique. The research findings were as follows: The external factors included the current conditions of the automotive industry, government’s policy related to the automotive industry, technology, labor market and human resource development systems of the country. The internal factors included management, productive management, organizational strategies, leadership, organizational culture and philosophy of human resource development. These factors were affected to the different concept of human resources development -the traditional human resource development and the strategies of human resource development. The organization focuses on human resources as intellectual capital and uses the strategies of human resource development in all development processes. The strategies of human resource development will enhance the ability of human resources in the organization and the country.

Keywords: Human Resource Development Strategy, Automotive industry, Eco-Cars, ASEAN.

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Authors: Wan Hasrulnizzam Wan Mahmood, Mohd Razali Muhamad, Nurulain Mat Tahar

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This paper is prepared to provide a review of how an automotive manufacturer, ISUZU HICOM Malaysia Co. Ltd. sustained the supply chain management after business process reengineering in 2007. One of the authors is currently undergoing industrial attachment and has spent almost 6 months researching in the production and operation management system of the company. This study was carried out as part of the tasks in the attachment program. The result shows that delivery lateness and outsourcing are the main barriers that affected productivity. From the gap analysis, the authors found that new business process operation had improved suppliers delivery performance.

Keywords: Supply Chain Management, Business Process Re- Engineering, Delivery, Outsourcing, Automotive Manufacturer.

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Authors: Williams S. Ebhota, Ckikaodili Virginia Ugwu

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Human ability is a major source of constraint to manufacturing industries in Nigeria. This paper therefore, discusses the importance of human influences on manufacturing and consequently to industrialization and National development. In this paper, the development of manufacturing was anchored on two main factors; Infrastructural Capacity Development (ICD) and Human Capacity Development (HCD). However, a wider view was given to the HCD and the various contemporary human capacity issues militating against manufacturing in Nigeria. It went further to discuss various ways of acquiring and upgrading workers’ skills and finally, suggestions were made on how to tackle the onerous human capacity issues in manufacturing.

Keywords: Manufacturing, Human, Capacity, Development, Innovation.

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Authors: Jirarat Teeravaraprug, Usawadee Inklay

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This paper gave an attempt in prioritizing information  technologies that organizations should give concentration. The case  study was organizations in the automotive assembly industry in  Thailand. Data were first collected to gather all information  technologies known and used in the automotive assembly industry in  Thailand. Five experts from the industries were surveyed based on  the concept of fuzzy DEMATEL. The information technologies were  categorized into six groups, which were communication, transaction,  planning, organization management, warehouse management, and  transportation. The cause groups of information technologies for each  group were analyzed and presented. Moreover, the relationship  between the used and the significant information technologies was  given. Discussions based on the used information technologies and  the research results are given.

 

Keywords: Information technology, automotive assembly industry, fuzzy DEMATEL.

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Authors: Un-Hwan Park, Jun-Hyeok Heo, In-Sung Lee, Tae-Hyeon Oh, Dae-Kyu Park

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Sound absorbing material is used as automotive interior material. Sound absorption coefficient should be predicted to design it. But it is difficult to predict sound absorbing coefficient because it is comprised of several material layers. So, its targets are achieved through many experimental tunings. It causes a lot of cost and time. In this paper, we propose the process to estimate the sound absorption coefficient with multi-layer structure. In order to estimate the coefficient, physical properties of each material are used. These properties also use predicted values by Foam-X software using the sound absorption coefficient data measured by impedance tube. Since there are many physical properties and the measurement equipment is expensive, the values predicted by software are used. Through the measurement of the sound absorption coefficient of each material, its physical properties are calculated inversely. The properties of each material are used to calculate the sound absorption coefficient of the multi-layer material. Since the absorption coefficient of multi-layer can be calculated, optimization design is possible through simulation. Then, we will compare and analyze the calculated sound absorption coefficient with the data measured by scaled reverberation chamber and impedance tubes for a prototype. If this method is used when developing automotive interior materials with multi-layer structure, the development effort can be reduced because it can be optimized by simulation. So, cost and time can be saved.

Keywords: Optimization design, multi-layer nonwoven, sound absorption coefficient, scaled reverberation chamber, impedance tubes.

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Authors: Ahmad Majdi Bin Abdul-Rani, Mesfin Gizaw, Yusri Yusof

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Researches related to standard product model and development of neutral manufacturing interfaces for numerical control machines becomes a significant topic since the last 25 years. In this paper, a detail description of STEP implementation on turnmill manufacturing has been discussed. It shows requirements of information contents from ISO14649 data model. It covers to describe the design of STEP-NC framework applicable to turn-mill manufacturing. In the framework, EXPRESS-G and UML modeling tools are used to depict the information contents of the system and established the bases of information model requirement. A product and manufacturing data model applicable for STEP compliant manufacturing. The next generation turn-mill operations requirements have been represented by a UML diagram. An object oriented classes of ISO1449 has been developed on Visual Basic dot NET platform for binding the static information model represented by the UML diagram. An architect of the proposed system implementation has been given on the bases of the design and manufacturing module of STEP-NC interface established. Finally, a part 21 file process plan generated for an illustration of turn-mill components.

Keywords: CAPP, ISO14649, Product modeling, STEP-NC

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Authors: Hendry Muljadi, Hideaki Takeda, Koichi Ando

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A manufacturing feature can be defined simply as a geometric shape and its manufacturing information to create the shape. In a feature-based process planning system, feature library that consists of pre-defined manufacturing features and the manufacturing information to create the shape of the features, plays an important role in the extraction of manufacturing features with their proper manufacturing information. However, to manage the manufacturing information flexibly, it is important to build a feature library that can be easily modified. In this paper, the implementation of Semantic Wiki for the development of the feature library is proposed.

Keywords: Manufacturing feature, feature library, feature ontology, process planning, Wiki, MediaWiki, Semantic Wiki.

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Authors: O. Kurtulus, C. Yavuz

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The end of the line controls of the finished products in the automotive industry is important. The control that has been conducted with the manual methods for the sliding doors tracks is not sufficient and faulty products cannot be identified. As a result, the customer has the faulty products. In the scope of this study, the design criteria of the PLC integrated modular end of line control unit has been examined, designed and manufactured to make the control of the 10 different track profile to 2 different vehicles with an objective to minimize the salvage costs by obtaining more sensitive, certain and accurate measurement results. In the study that started with literature and patent review, the design inputs have been specified, the technical concept has been developed, computer supported mechanic design, control system and automation design, design review and design improvement have been made. Laser analog sensors at high sensitivity, probes and modular blocks have been used in the unit. The measurement has been conducted in the system and it is observed that measurement results are more sensitive than the previous methods that we use.

Keywords: Control unit design, end of line, modular design, sliding door system.

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Authors: Manuel Seidel, Rainer Seidel, Des Tedford, Richard Cross, Logan Wait

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Small and Medium Sized Enterprises (SMEs) play an important role in many economies. In New Zealand, for example, 97% of all manufacturing companies employ less than 100 staff, and generate the predominant part of this industry sector-s economic output. Manufacturing SMEs as a group also have a significant impact on the environment. This situation is similar in many developed economies, including the European Union. Sustainable economic development therefore needs to strongly consider the role of manufacturing SMEs, who generally find it challenging to move towards more environmentally friendly business practices. This paper presents a systems thinking approach to modelling and understanding the factors which have an influence on the successful uptake of environmental practices in small and medium sized manufacturing companies. It presents a number of causal loop diagrams which have been developed based on primary action research, and a thorough understanding of the literature in this area. The systems thinking model provides the basis for further development of a strategic framework for the successful uptake of environmental innovation in manufacturing SMEs.

Keywords: Environmentally benign manufacturing, SMEs, Systems modeling.

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Authors: M. Othman, N. Bhuiyan, G. J. Gouw

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In today-s global and competitive market, manufacturing companies are working hard towards improving their production system performance. Most companies develop production systems that can help in cost reduction. Manufacturing systems consist of different elements including production methods, machines, processes, control and information systems. Human issues are an important part of manufacturing systems, yet most companies do not pay sufficient attention to them. In this paper, a workforce planning (WP) model is presented. A non-linear programming model is developed in order to minimize the hiring, firing, training and overtime costs. The purpose is to determine the number of workers for each worker type, the number of workers trained, and the number of overtime hours. Moreover, a decision support system (DSS) based on the proposed model is introduced using the Excel-Lingo software interfacing feature. This model will help to improve the interaction between the workers, managers and the technical systems in manufacturing.

Keywords: Decision Support System, Human Factors, Manufacturing System, Workforce Planning.

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Authors: T. Häfele, J. Kaspar, M. Vielhaber, W. Calles, J. Griebsch

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The demand for an increasing diversification of the product spectrum associated with the current huge customization desire and subsequently the decreasing unit quantities of each production lot is gaining more and more importance within a great variety of industrial branches, e.g. automotive industry. Nevertheless, traditional product development and production processes (molding, extrusion) are already reaching their limits or fail to address these trends of a flexible and digitized production in view of a product variability up to lot size one. Thus, upcoming innovative production concepts like the additive manufacturing technology basically create new opportunities with regard to extensive potentials in product development (constructive optimization) and manufacturing (economic individualization), but mostly suffer from insufficient strength regarding structural components. Therefore, this contribution presents an innovative technological and procedural conception of a hybrid additive manufacturing process (fiber-reinforced sandwich structures based on selective laser sintering technology) to overcome these current structural weaknesses, and consequently support the design of complex lightweight components.

Keywords: Additive manufacturing, fiber-reinforced plastics, hybrid design, lightweight design.

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Authors: Susana G. Azevedo, Helena Carvalho, V. Cruz –Machado

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The supply chains (SCs) have to appeal to new management paradigms to improve their ability to respond rapidly and cost effectively to unpredictable changes in markets and increasing levels of environmental turbulence, both in terms of volume and variety. In this highly demanded context, the Agile paradigm provides the capabilities to SC quickly adapt to changes in the market requirements. The purpose of this paper is to suggest an Agile Index to assess the agility of the automotive companies and corresponding SCs. The proposed integrated assessment model incorporates Agile practices weighted according to their importance to the automotive SC competitiveness and obtained from the Delphi technique.

Keywords: Agile, Supply chain management, Index, Delphitechnique.

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Authors: Manouchehre Ansari, Mahmoud Dehghan Nayeri, Reza Yousefi Zenouz

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In order to develop any strategy, it is essential to first identify opportunities, threats, weak and strong points. Assessment of technology level provides the possibility of concentrating on weak and strong points. The results of technology assessment have a direct effect on decision making process in the field of technology transfer or expansion of internal research capabilities so it has a critical role in technology management. This paper presents a conceptual model to analyze the technology capability of a company as a whole and in four main aspects of technology. This model was tested on 10 automotive parts manufacturers in IRAN. Using this model, capability level of manufacturers was investigated in four fields of managing aspects, hard aspects, human aspects, and information and knowledge aspects. Results show that these firms concentrate on hard aspect of technology while others aspects are poor and need to be supported more. So this industry should develop other aspects of technology as well as hard aspect to have effective and efficient use of its technology. These paper findings are useful for the technology planning and management in automotive part manufactures in IRAN and other Industries which are technology followers and transport their needed technologies.

Keywords: Technology, Technological evaluation, TechnologyMaturity

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Authors: Mohamed. A. Shrud, Ahmad H. Kharaz, Ahmed. S. Ashur, Ahmed Faris, Mustafa Benamar

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This paper will focus on modeling, analysis and simulation of a 42V/14V dc/dc converter based architecture. This architecture is considered to be technically a viable solution for automotive dual-voltage power system for passenger car in the near further. An interleaved dc/dc converter system is chosen for the automotive converter topology due to its advantages regarding filter reduction, dynamic response, and power management. Presented herein, is a model based on one kilowatt interleaved six-phase buck converter designed to operate in a Discontinuous Conduction Mode (DCM). The control strategy of the converter is based on a voltagemode- controlled Pulse Width Modulation (PWM) with a Proportional-Integral-Derivative (PID). The effectiveness of the interleaved step-down converter is verified through simulation results using control-oriented simulator, MatLab/Simulink.

Keywords: Automotive, dc-to-dc power modules, design, interleaved, Matlab\Simulink and PID control.

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Authors: Olaniyi O. Omoyajowo

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To be successful in today’s competitive global environment, manufacturing industry must be able to respond quickly to changes in technology. These changes in technology introduce new risks and hazards. The management of risk/hazard in a manufacturing process recommends method through which the success rate of an organization can be increased. Thus, there is a continual need for manufacturing industries to invest significant amount of resources in risk management, which in turn optimizes the production output and profitability of any manufacturing industry (if implemented properly). To help improve the existing risk prevention and mitigation practices in Small and Medium Enterprise (SME) in Nigeria Manufacturing Industries (NMI), the researcher embarks on this research to develop a systematic Risk Management process.

Keywords: Manufacturing industries, production output, risk, risk management, SMEs.

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Authors: Ventura Assuncao

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In automotive systems almost all steps concerning the calibration of several control systems, e.g., low idle governor or boost pressure governor, are made with the vehicle because the timeto- production and cost requirements on the projects do not allow for the vehicle analysis necessary to build reliable models. Here is presented a procedure using parametric and NN (neural network) models that enables the generation of vehicle system models based on normal ECU engine control unit) vehicle measurements. These models are locally valid and permit pre and follow-up calibrations so that, only the final calibrations have to be done with the vehicle.

Keywords: Automotive systems, neuro-hybrid models, demodulator, nonlinear systems, identification, and neural networks.

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Authors: Naveen Virmani, Rajeev Saha, Rajeshwar Sahai

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In today’s market, striving hard has become necessary for the industries to survive due to the intense competition and globalization. In earlier days, there were few sellers and limited numbers of buyers, so customers were having fewer options to buy the product. But today, the market is highly competitive and volatile. Industries are focusing on robotics, advance manufacturing methods like AJM (Abrasive Jet Machining), EDM (Electric Discharge Machining), ECM (Electrochemical Machining) etc., CAD/CAM, CAE to make quality products and market them in shortest possible time. Leagile manufacturing system is ensuring best available solution at minimum cost to meet the market demand. This paper tries to assimilate the concept of Leagile manufacturing system in today’s scenario and evaluating key factors affecting Leagile manufacturing using digraph technique.

Keywords: Agile manufacturing, digraph, lean manufacturing, leagile manufacturing.

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Authors: Louis Denis Kevin Catherine, Raja Aziz Raja Ma’arof, Azrina Arshad, Sangeeth Suresh

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Machining parameters are very important in determining the surface quality of any material. In the past decade, some new engineering materials were developed for the manufacturing industry which created a need to conduct an investigation on the impact of the said parameters on their surface roughness. Polyurethane (PU) block is widely used in the automotive industry to manufacture parts such as checking fixtures that are used to verify the dimensional accuracy of automotive parts. In this paper, the design of experiment (DOE) was used to investigate on the effect of the milling parameters on the PU block. Furthermore, an analysis of the machined surface chemical composition was done using scanning electron microscope (SEM). It was found that the surface roughness of the PU block is severely affected when PU undergoes a flood machining process instead of a dry condition. In addition the stepover and the silicon content were found to be the most significant parameters that influence the surface quality of the PU block.

Keywords: Polyurethane (PU), design of experiment (DOE), scanning electron microscope (SEM), surface roughness.

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Authors: Jung-Chuan Chou, Chang-Chi Lee

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A measurement system was successfully fabricated to detect ion concentrations (hydrogen and chlorine) in this study. PIC18F4520, the microcontroller was used as the control unit in the measurement system. The measurement system was practically used to sense the H+ and Cl- in different examples, and the pH and pCl values were exhibited on real-time LCD display promptly. In the study, the measurement method is used to judge whether the response voltage is stable. The change quantity is smaller than 0.01%, that the present response voltage compares with next response voltage for H+ measurement, and the above condition is established only 6 sec. Besides, the change quantity is smaller than 0.01%, that the present response voltage compares with next response voltage for Clmeasurement, and the above condition is established only 5 sec. Furthermore, the average error quantities would also be considered, and they are 0.05 and 0.07 for measurements of pH and pCl values, respectively.

Keywords: Chlorine ion sensor, hydrogen ion sensor, microcontroller, response voltage.

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Authors: S. J. Arif

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In the presented technique, a simple method is given for accurate measurement and control of power frequency deviation. The sinusoidal signal for which the frequency deviation measurement is required is transformed to a low voltage level and passed through a zero crossing detector to convert it into a pulse train. Another stable square wave signal of 10 KHz is obtained using a crystal oscillator and decade dividing assemblies (DDA). These signals are combined digitally and then passed through decade counters to give a unique combination of pulses or levels, which are further encoded to make them equally suitable for both control applications and display units. The developed circuit using discrete components has a resolution of 0.5 Hz and completes measurement within 20 ms. The realized circuit is simulated and synthesized using Verilog HDL and subsequently implemented on FPGA. The results of measurement on FPGA are observed on a very high resolution logic analyzer. These results accurately match the simulation results as well as the results of same circuit implemented with discrete components. The proposed system is suitable for accurate measurement and control of power frequency deviation.

Keywords: Digital encoder for frequency measurement, frequency deviation measurement, measurement and control systems, power systems.

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Authors: M. N. Osman Zahid, K. Case, D. Watts

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This paper reports an advanced approach in the application of CNC machining for rapid manufacturing processes (CNC-RM). The aim of this study is to improve the quality of machined parts by introducing different cutting tools during finishing operations. As the cutting is performed in different directions, the surfaces presented on part can be classified into several categories. Therefore, suitable cutting tools are assigned to machine particular surfaces and to improve the quality. Experimental studies have been carried out by fabricating several parts based on the suggested approach. The results provide further support for implementing this approach in rapid machining processes.

Keywords: CNC machining, End mill tool, Finishing operation, Rapid manufacturing.

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Authors: Salman Pervaiz, Ibrahim Deiab, Amir Rashid, Mihai Nicolescu, Hossam Kishawy

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Greenhouse gases (GHG) emissions impose major threat to global warming potential (GWP). Unfortunately manufacturing sector is one of the major sources that contribute towards the rapid increase in greenhouse gases (GHG) emissions. In manufacturing sector electric power consumption is the major driver that influences CO2 emission. Titanium alloys are widely utilized in aerospace, automotive and petrochemical sectors because of their high strength to weight ratio and corrosion resistance. Titanium alloys are termed as difficult to cut materials because of their poor machinability rating. The present study analyzes energy consumption during cutting with reference to material removal rate (MRR). Surface roughness was also measured in order to optimize energy consumption.

Keywords: Energy Consumption, CO2 Emission, Ti6Al4V.

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Authors: Hamed Afrasiab, Saeed Khodaygan

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Prediction of machining process capability in the design stage plays a key role to reach the precision design and manufacturing of mechanical products. Inaccuracies in machining process lead to errors in position and orientation of machined features on the part, and strongly affect the process capability in the final quality of the product. In this paper, an efficient systematic approach is given to investigate the machining errors to predict the manufacturing errors of the parts and capability prediction of corresponding machining processes. A mathematical formulation of fixture locators modeling is presented to establish the relationship between the part errors and the related sources. Based on this method, the final machining errors of the part can be accurately estimated by relating them to the combined dimensional and geometric tolerances of the workpiece – fixture system. This method is developed for uncertainty analysis based on the Worst Case and statistical approaches. The application of the presented method is illustrated through presenting an example and the computational results are compared with the Monte Carlo simulation results.

Keywords: Process capability, machining error, dimensional and geometrical tolerances, uncertainty analysis.

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