- Email: [email protected]
Expert system aims to boost Europe's use of PM
Expert system aims to boost Europe's use of PM ith Europe's automotive industry lagging behind both North America and Japan in the uptake of powder metallurgy (PM) parts, UK researchers are proposing to develop an artificial intelligence system to assist designers in using the technology. Known as a knowledge based (or expert) system, the computer programme would integrate PM knowledge, in areas such as powder selection, design criteria and process optimization, with design evaluation software to enable engineers to make the best use of the PM process. The system would enable part development to be done more simply and quickly, while also allowing designers with little familiarity with PM to use the process. Dr Sagar Midha of the the University of West of England in Bristol is coordinating the project and is currently seeking support from Europe's PM community. Midha intends to assemble a collaborative research programme with input from powder suppliers part makers, and end users, as well as other software houses engaged in developing design solutions for manufacturing companies and research establishments engaged in PM work Once the team has been assembled, Midha plans to submit the proposal for European research funding.
W
Knowledge based systems Knowledge based systems (IlliS) have already been successfully applied in many fields of manufacturing including de-
=
[{(OnRGt! 12 MPR November 1995
sign, process optimization, con- hybrid system based on existing dition monitoring and system expert knowledge, published control. Midha says KBS is a data and results of experimenparticularly effective tool for tal work at UWE. using existing knowledge on Cost Estimator: this modcomplicated processes to help ule will provide an estimate of engineers improve process per- the cost of component manufacformance and product quality. ture using PM. The component He says it is particularly useful mass is inferred from its solid in cases where the knowledge on model to allow the cost of the the process is vast, diverse and raw material to be calculated. scattered, such as with PM. An estimation of tooling cost, The application of KBS in based on design features, will be the field of PMis not totally new. also attempted in the future. A few expert systems have been Midha believes a more comdeveloped over the years in prehensive application of KBS areas such as hot isostatic to PM would have a major pressing (HIP). Midha's team impact on the industry, enat the Faculty of Enginering at abling components to be deUniversity of West of England signed more quickly and has already begun to develop a cheaply, as well as making the KBS advisory system, which has technology more accessible. "This would ensure the three main modules: Interactive Design Advi- competitiveness of the Eursor: using information gener- opean PM industry into the ated by an AutoCad solid next century and its successful modeller, this system analyzes expansion into new markets," design features to deduce their Midha says. Midha says providing an suitability for the powder forming process. As well as providing integrated system for the optirecommendations, the system mum and concurrent design and implements design modifica- manufacture of PM products, tions for appraisal by the de- however, will require further sign engineer. As the first stage research to develop the followin the development of the ing capabilities: system, a 'Design Data InterIntelligent Interactive Depreter' for flanged bearings has sign System: providing an inbeen implemented using Auto- teractive environment for the CAD, dBaseIV, and the XiPlus design engineer at both concepexpert system shell. tual and detailed design stages. Process Advisory System At the conceptual design stage for Iron Products: this system the information on the functionuses rule-based artificial intelli- ality and mechanical specificagence, as well as empirical data tion of the product is entered. modelling techniques, to recom- This information is analyzed to mend PM material and process detect any major problem in parameters to meet specified terms of PM application. An properties in terms of tensile interactive analysis of the destrength, elongation and impact sign features as well as approresistance. The system will be a priate assumptions about the
Would you like to know more about our products? For first information use the product finder!
PM TECHNOLOGY TRENDS possible later design decisions would be used to provide early advice on the design feasibility, suitable powder materials, alternative PM techniques and a first estimate of the costs. At the detailed design phase, a progressively more accurate design interrogation would be carried out to provide an optimized design for PM in terms of manufacturing ease, product quality and cost. Process Optimization System: based on product design and mechanical specifications, this system would provide an Intelligent tool for assessment of raw material and alternative PM processes to ensure the desired product weight , mechanical specification including tensile properties and fatigue behaviour. The system will comprise a 'Mat er ia l Selection System' which would match the required part specifications with available powders and a 'Process Simulation System' which would use appropriate process models for compaction and slntering to simulate the effect of different process parameters and evaluate the final product properties and the associated
costs. Further research in process modelling would be carried out in support of the KB system development. An 'Intelligent Cost Analysis System' would provide cost estimates based on a combination of data on design complexity, required raw material and processing costs. Intelligent Process Control: a combination of improved sensor and instrumentation technology and appropriate control strategies would be sought to enable enhanced and consistent material properties and dimensional accuracy. Feedback about the required and achieved product specifications would be used to provide "historical cases" to update and optimize the knowledge base used by different systems.
System benefits Midha sees the development of a KBS as a means of pulling together the recent technological advances that have been made in PM in a wide number of areas. He says it will offer a range of benefits to the industry including the reduction of design-to-manufacture time cycles, thereby allowing the industry to
respond more quickly to market requirements. It will aid in the selection of raw materials and process parameters, which in turn will provide early and reliable product costings. Midha also believes it will lead to greater awareness and application of PM technology in Europe, in the automotive and other industries. At the present time, the average European car contains about 5.7 kg of PM components, compared with 6.6 kg in Japan and 12.26 kg in North America. Midha says although the low growth of PM In Europe can be attributed to a number of factors, lack of awareness of the technology among engineers remains one of the most significant barriers. "Compared with the better understood conventional processes, such as the machining of fully dense materials, PM is considered to be a complex and difficult to implement technology," Midha says. "The highly multi-disciplinary nature of the involved processes further adds to this problem. For Europe to benefit from the advantages offered by PM, this obstacle must be overcome." •
MPR November 1995 13
W
Knowledge based systems Knowledge based systems (IlliS) have already been successfully applied in many fields of manufacturing including de-
=
[{(OnRGt! 12 MPR November 1995
sign, process optimization, con- hybrid system based on existing dition monitoring and system expert knowledge, published control. Midha says KBS is a data and results of experimenparticularly effective tool for tal work at UWE. using existing knowledge on Cost Estimator: this modcomplicated processes to help ule will provide an estimate of engineers improve process per- the cost of component manufacformance and product quality. ture using PM. The component He says it is particularly useful mass is inferred from its solid in cases where the knowledge on model to allow the cost of the the process is vast, diverse and raw material to be calculated. scattered, such as with PM. An estimation of tooling cost, The application of KBS in based on design features, will be the field of PMis not totally new. also attempted in the future. A few expert systems have been Midha believes a more comdeveloped over the years in prehensive application of KBS areas such as hot isostatic to PM would have a major pressing (HIP). Midha's team impact on the industry, enat the Faculty of Enginering at abling components to be deUniversity of West of England signed more quickly and has already begun to develop a cheaply, as well as making the KBS advisory system, which has technology more accessible. "This would ensure the three main modules: Interactive Design Advi- competitiveness of the Eursor: using information gener- opean PM industry into the ated by an AutoCad solid next century and its successful modeller, this system analyzes expansion into new markets," design features to deduce their Midha says. Midha says providing an suitability for the powder forming process. As well as providing integrated system for the optirecommendations, the system mum and concurrent design and implements design modifica- manufacture of PM products, tions for appraisal by the de- however, will require further sign engineer. As the first stage research to develop the followin the development of the ing capabilities: system, a 'Design Data InterIntelligent Interactive Depreter' for flanged bearings has sign System: providing an inbeen implemented using Auto- teractive environment for the CAD, dBaseIV, and the XiPlus design engineer at both concepexpert system shell. tual and detailed design stages. Process Advisory System At the conceptual design stage for Iron Products: this system the information on the functionuses rule-based artificial intelli- ality and mechanical specificagence, as well as empirical data tion of the product is entered. modelling techniques, to recom- This information is analyzed to mend PM material and process detect any major problem in parameters to meet specified terms of PM application. An properties in terms of tensile interactive analysis of the destrength, elongation and impact sign features as well as approresistance. The system will be a priate assumptions about the
Would you like to know more about our products? For first information use the product finder!
PM TECHNOLOGY TRENDS possible later design decisions would be used to provide early advice on the design feasibility, suitable powder materials, alternative PM techniques and a first estimate of the costs. At the detailed design phase, a progressively more accurate design interrogation would be carried out to provide an optimized design for PM in terms of manufacturing ease, product quality and cost. Process Optimization System: based on product design and mechanical specifications, this system would provide an Intelligent tool for assessment of raw material and alternative PM processes to ensure the desired product weight , mechanical specification including tensile properties and fatigue behaviour. The system will comprise a 'Mat er ia l Selection System' which would match the required part specifications with available powders and a 'Process Simulation System' which would use appropriate process models for compaction and slntering to simulate the effect of different process parameters and evaluate the final product properties and the associated
costs. Further research in process modelling would be carried out in support of the KB system development. An 'Intelligent Cost Analysis System' would provide cost estimates based on a combination of data on design complexity, required raw material and processing costs. Intelligent Process Control: a combination of improved sensor and instrumentation technology and appropriate control strategies would be sought to enable enhanced and consistent material properties and dimensional accuracy. Feedback about the required and achieved product specifications would be used to provide "historical cases" to update and optimize the knowledge base used by different systems.
System benefits Midha sees the development of a KBS as a means of pulling together the recent technological advances that have been made in PM in a wide number of areas. He says it will offer a range of benefits to the industry including the reduction of design-to-manufacture time cycles, thereby allowing the industry to
respond more quickly to market requirements. It will aid in the selection of raw materials and process parameters, which in turn will provide early and reliable product costings. Midha also believes it will lead to greater awareness and application of PM technology in Europe, in the automotive and other industries. At the present time, the average European car contains about 5.7 kg of PM components, compared with 6.6 kg in Japan and 12.26 kg in North America. Midha says although the low growth of PM In Europe can be attributed to a number of factors, lack of awareness of the technology among engineers remains one of the most significant barriers. "Compared with the better understood conventional processes, such as the machining of fully dense materials, PM is considered to be a complex and difficult to implement technology," Midha says. "The highly multi-disciplinary nature of the involved processes further adds to this problem. For Europe to benefit from the advantages offered by PM, this obstacle must be overcome." •
MPR November 1995 13