- Email: [email protected]
Virtual reality barrel shaft design and assembly planning accompany with CAM
Available online at www.sciencedirect.com Available online at www.sciencedirect.com
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Available Availableonline onlineatatwww.sciencedirect.com www.sciencedirect.com Procedia Manufacturing 00 (2018) 000–000 Procedia Manufacturing 00 (2018) 000–000
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www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia
Procedia Manufacturing 30 (2019) 677–684 Procedia Manufacturing 00 (2017) 000–000 www.elsevier.com/locate/procedia
14th Global Congress on Manufacturing and Management (GCMM-2018) 14th Global Congress on Manufacturing and Management (GCMM-2018)
Virtual reality barrel shaft design and assembly planning accompany Virtual reality barrel shaft design assembly planning accompany with and CAM Manufacturing Engineering Society International Conference 2017, MESIC 2017, 28-30 June witha*CAM T. Channarong , and B. Suthepb Vigo (Pontevedra), Spain b a* T.2017, Channarong , and B. Suthep
Industrial Engineering Department, Princess of Naradhiwas University, 99 Khok Kian Muang Narathiwat, Narathiwat 96000, Thailand a Industrial Engineering Department, Princess of Naradhiwas 99 Khok Muang Narathiwat, 96000, Thailand Production Engineering Department, King Mongkut’s UniversityUniversity, of Technology NorthKian Bangkok, 1518 PracharatNarathiwat 1 Road, Wongsawang Bangsue b Bangkok Thailand Production Engineering Department, King Mongkut’s University of 10800, Technology North Bangkok, 1518 Pracharat 1 Road, Wongsawang Bangsue Bangkok 10800, Thailand a
Costing models for capacity optimization in Industry 4.0: Trade-off between used capacity and operational efficiency
b
Abstract A. Santanaa, P. Afonsoa,*, A. Zaninb, R. Wernkeb Abstract a University of Minho, Portugal This paper proposes the virtual reality concept to design and 4800-058 assemblyGuimarães, planning for a barrel shaft. The shaft model was created on b Unochapecó, 89809-000 Chapecó, SC, Brazil This proposes the virtual concept to design and assembly planning for aasbarrel shaft.method. The shaft model was created on CAMpaper and digital verification forreality effective functional design together with simulation traditional Presently, virtual reality CAM and digital verificationtofor effective functional design together with simulation as traditional Presently, virtualinreality technology is sophisticated mechanical components design and assembly animation which canmethod. help a design engineer order technology is sophisticated to mechanical components design optimization. and assemblyCollaborative animation which canenvironment help a design engineer order to show possibility alternative assembly planning and achieve virtual system wasinused to to show assembly planning and achieve optimization. Collaborative virtual environment system was used to create thepossibility assemblyalternative plan animation. Abstract create the assembly plan animation. © 2018 The Authors. Published by Elsevier Ltd. © 2018 2019 The Authors. by Elsevier Ltd. Under the concept of "Industry productionlicense processes will be pushed to be increasingly interconnected, © The Authors. Published by Elsevier Ltd. ) This is an open accessPublished article under the4.0", CC BY-NC-ND (https://creativecommons.org/licenses/by-nc-nd/4.0/ This is an open access article under the CC BY-NC-ND licensemuch (https://creativecommons.org/licenses/by-nc-nd/4.0/) information based on a real time basis and, necessarily, more this context, optimization This is an and openpeer-review access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/ ) and Selection under responsibility of the scientific committee efficient. of the 14thInGlobal Congresscapacity on Manufacturing Selection and peer-review under responsibility of the scientific committee of the 14th Global Congress on Manufacturing and goes beyond the traditional aimresponsibility of capacity maximization, for organization’s profitability and value. Selection and(GCMM-2018). peer-review under of the scientificcontributing committee ofalso the 14th Global Congress on Manufacturing and Management Management (GCMM-2018). Management Indeed, lean(GCMM-2018). management and continuous improvement approaches suggest capacity optimization instead of
Keywords: VirtualThe Reality Design Assembly Planning, Barrel Shaft, Digitalmodels Verification, Optimization, maximization. study ofand capacity optimization and costing is an importantCAM research topic that deserves Keywords: Virtual Reality Design Assembly Planning, Barrel perspectives. Shaft, Digital Verification, Optimization, contributions from both the and practical and theoretical This paper presents CAM and discusses a mathematical model for capacity management based on different costing models (ABC and TDABC). A generic model has been *Corresponding Author E. mail address: [email protected] developed andAuthor it wasE.used to analyze idle capacity and to design strategies towards the maximization of organization’s *Corresponding mail address: [email protected] value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity 1. Introduction optimization might hide operational inefficiency. 1. Introduction © 2017 The Authors. Published by Elsevier B.V. Currently, the virtual reality (VR) technology is used extensively by covers almost all professions [1]. Due to the Peer-review under of (VR) the scientific committee of the Manufacturing Engineering Society International Conference Currently, theresponsibility virtual reality used extensively by potential covers almost all professions [1]. Due to the flexibility of the VR application suchtechnology as systems is provide an enormous for enhancing the 3 D visualization 2017. flexibility the VR application as systems provide an enormous for enhancing the 3 D visualization linked withof interaction device. Itsuch includes the open dynamic engine potential (ODE) and collision detection module [2]. linked with interaction device. It includesmedical, the open dynamic engine and (ODE) and fields. collision module Especially, application in engineering, military, education another Thisdetection introduction aims[2]. to Keywords: Costits Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency Especially, in engineering, medical, education and another fields. Thisindustries introduction aims to present alsoits theapplication context of the research respect to the military, mechanical parts design for manufacturing in Thailand. present contextexpects of the research to the mechanical parts design for manufacturing in Thailand. Becausealso thisthe research to buildrespect new knowledge for the benefit of Thailand’s economyindustries which relevant to the Because this research expects to build newtoknowledge for theprocess. benefit of which relevant to the design process and simulate throughout manufacturing It Thailand’s focuses oneconomy the movement simulation of 1. Introduction design process and simulate throughout to manufacturing process. It focuses on the movement simulation of The cost of idle capacity is a fundamental information for companies and their management of extreme importance 2351-9789 2018 The Authors. Published by Elsevier in modern©production systems. In general, it isLtd. defined as unused capacity or production potential and can be measured This is an open access under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) 2351-9789 © 2018 Thearticle Authors. Published by Elsevier Ltd. in several ways: tons of production, available hours of manufacturing, etc. The management of the idle capacity Selection and peer-review under responsibility of the scientific committee of the 14th Global Congress on Manufacturing and Management This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) * Paulo Afonso. Tel.: +351 253responsibility 510 761; fax: of +351 604 741 (GCMM-2018). Selection and peer-review under the 253 scientific committee of the 14th Global Congress on Manufacturing and Management E-mail address: [email protected] (GCMM-2018).
2351-9789 Published by Elsevier B.V. Ltd. 2351-9789©©2017 2019The TheAuthors. Authors. Published by Elsevier Peer-review underaccess responsibility the scientific committee oflicense the Manufacturing Engineering Society International Conference 2017. This is an open article of under the CC BY-NC-ND (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection and peer-review under responsibility of the scientific committee of the 14th Global Congress on Manufacturing and Management (GCMM-2018). 10.1016/j.promfg.2019.02.063
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mechanical components in VR environment [3]. Furthermore, to simulate the tools trajectory for CNC milling and turning machines are performed by 4-5D contouring through computer aided manufacturing (CAM) software [4]. The experimental methods are expected to determine design and simulate tasks through collaborative virtual reality environment system (CVRES). The experiment is used to validate and compare with the performance of CVRES to optimize the design and movement simulation tasks. The different various of CVRES respect to arrangements of the engines/equipment as well as applications. A CVRES consist of several VR modules and the modules must be connected to interaction device to support an expected task. In this context to achieve assess barrel shaft transmissions for motion simulation experiment. The CVRES consist of analysis module and inserted with the preliminary sensors: stopwatch, orientation, and instability sensor. In this research has selected the most appropriate virtual environment for this context using a haptic arm with force-feedback combined with 3D glasses on 2D wall screen [5]. By the time that the design process ends, the next step is analytical process which the most appropriate tools selection and trajectories for CNC milling & turning machines. The main goal is not to compare a few specific environments but to the comparison itself. Incidentally, the complexity of design or global innovative design are challenges for designers and engineers. But the main objective is to offer them a correct design and simulation framework as well as the application of the tools technologies to suit the context. Nowadays, the tools used (CAD/CAM/CAE/CNC) for manufacturing industries are widely popular for designer, engineers, and manufacturing experts [6]. Meanwhile, the VR technology in high performance platform but they often do not know which platform or environment will be the most effective for the expected tasks. If our research is successful as expected, we may have use VR technology to develop capabilities design and manufacturing. Particularly, for the manufacturing of mechanical parts in designing activities such as assembly and simulation [7]. 2. Research Methodology The goal of this research was expected to build high level assessment technique to assess motion performance and to compare barrel shaft in different dimensions. We propose a process to measure objective of criteria using basic level measures. The VR session is instrumented with primary sensors that can be reported automatically. This research proposes to achieve VR environment that suits the context of design, assembly and simulation activities. The general structure and procedure of research methodology for this context includes: system and implementation methodology to reach the desired goals which are shown in Fig. 1.
The general structure and procedure of research methodology The desired goals
System and implementation methodology
Manufacturing Preparation
CVRES
Implementation
User
Senses (Hand & Eye)
Machines Selection
Task or context
Movement Simulation
- Lathe with live tooling -Vertical mill 5 axis
System or Software
CVE
Tools trajectory simulation
Environment
Physical Environments
Database analysis
Tool management
Fig. 1. The general structure and procedure of research methodology
- Generic tools database - Personal tools database
T. Channarong et al. / Procedia Manufacturing 30 (2019) 677–684 T. Channarong and B. Suthep / Procedia Manufacturing 00 (2018) 000–000
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2.1 System and implementation methodology The CVRES module consists of four core components; the user or participant, interacts with computer operating systems, the task or context, is the activity related to the design phase and will be tested in this research for motion tasks, the system or software which is called a Collaborative Virtual Reality Environment System (CVES), the environment, defines the used hardware with various combinations of interaction and visualization which it has defined physical environments: a haptic arm with force-feedback combined with 3D glasses on 2D wall screen as shown in the Fig 2.
Fig. 2. A haptic arm interface modeled haption Virtuose 6D35-45
2.2 Manufacturing preparation method This section contains information about the manufacturing process and operations. Manufacturing are processes defined to produce a product or sub-product [8]. The manufacturing process determines the required operational resources, setup time, production time, and cost calculation [9]. In this context, machines and tools are selected to produce virtually a barrel shaft manufacturing process with a good quality, consistently servicing the parts. The manufacturing preparation method for this experiment has been created using the Top Solid v 7.11 program. The main context in this section is the selection of machinery to use for manufacturing process. They are CNC machines; CNC lathe and CNC vertical milling. The CNC lathe machine can perform together with milling operation. It is able to work as milling, drilling, and grinding tasks as shown in the Fig. 3. The 5 axes CNC Vertical mill machine is shown in the Fig 4.
Fig. 3. Virtual CNC Lathe machine
4 680
T. Channarong and B. Suthep / Procedia Manufacturing 00 (2018) 000–000 T. Channarong et al. / Procedia Manufacturing 30 (2019) 677–684
Fig. 4. CNC 5-axis milling machine
2. System overview System overview for the general purpose of 3D visualization and interaction devices manipulation. The CVRES consists of several modules but for this context selected the following ones: a communication server, a configuration editor, a 3D viewer enabling virtual reality usage, an analysis module, and haptic connector. The server dispatches events between the various modules. Moreover, CVRES is a multi-agent-based system dedicated to collaborating within a virtual/augmented environment. A socket-based communication system is employed to ensure the communication between agents. Every agent oversees a behavior of the global virtual environment. The various CVRES modules used in our experiment. In the current experiment, the expected sub-behaviors correspond to five modules;
CVRES-Editor module
The CVRES-Editor module enables to import and to export the object format. Moreover, in this module we can modify the scene (colors) and provide access to any state value of the scene. “It is necessary to import” a STL or OBJ file format into CVRES Editor before working with the collaboration virtual reality environment software.
CVRES-Viewer module
CVRES-Viewer oversees creating the 3D visualization and sending it to the final display which can be holographic, stereoscopic or a simple 2D screen. CVRES Viewer opens 3D windows which can display diverse imported 3D objects by “wave front OBJect” file format, it is simply referred to as the (OBJ) file format. Concerning the 3D models imported for this research, all elements were imported and exported in OBJ data formats by using CAD software. The OBJ file format can be imported directly into CVRES Viewer module which generates the scene and 3D models.
CVRES-ODE module
The CVRES-ODE module is especially important for simulating dynamics articulated rigid body, which will be the invisible model for collision detection and force-feedback. It is particularly good for simulating moving objects in changeable virtual reality environments because it is quite fast, robust, and stable. Collision detection prevents part interpenetration for the user regarding how to move position and orientation of the parts to finish the operation.
CVRES-Happy module
CVRES-Happy is a module to take in charge the connection with a haptic arm. It can survey the position of the human operator’s hand and it drives the arm actuators to apply a force feed-back, if feedback is activated [10] during
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virtual assembly and simulate tasks. The haptic arm available in our laboratory, is the Virtuose 6D35-45 which is composed of two main articulated segments fixed on a rotating base.
CVRES-Analysis module
CVRES-Analysis module has several basic sensors which can be selected and adjusted from the CVRES-editor. This research selected two basic sensors to evaluate the way users performing the movement simulation tasks during our experiment. These sensors are the duration and instability sensors. The duration sensor measures the duration of the experiments. The duration is the interval of time between the event launching the analysis and the event stopped the analysis. No special attributes are expected to define this sensor since it is a global sensor associated with the whole analysis. The instability sensor intends to measure the evolution of a position during a lap of time. Instability sensor evaluates the gesture instability. The position of two points in a frame defined by a transformation matrix defining the position of the manipulated object is continuously analyzed. The trajectory of these points is linearized by small intervals of time and the sensor compares the real path length of the point respecting to the linearized trajectory interval per interval. The ratio gives an idea of the oscillation of the trajectory around a more efficient straight path. It depicts the gesture shivers. This ratio is recorded by the analysis module for every conducted experiment. A task can be defined, processed and repeated several times as a record file provides the raw result of these basic sensors. 3. CAD for VR environment preparation Nowadays, 3D geometric models is created using CAD software by relying on the expertise of designers, engineers, and manufacturing experts. In general, CAD software is efficient in import and export in various file formats such as Stereo Lithography (STL), Standard for Exchange of Product model data (STEP AP203), Virtual Reality Modeling Language (VRML), and so on [10-12]. In this research, the 3D models are individually exported into STL file formats and transformed into CVRES-Editor module. For this reason, the translation mode is a 3D model of the VR environment is thus, once the initial process for working on CVRES-Viewer module. Furthermore, to reopen the STL file merge nodes and to export the meshes into OBJ files format. Besides, choosing to use OBJ file format because it can compress the file well and an intermediary step is performed through the STL to OBJ conversion. Particularly, a barrel shaft mechanism movement simulation able to interact with the CVRES-ODE module. For this research, the kinematics constraints of barrel shaft was rebuilt from scratch directly of the CVRES-ODE module. The operation will be more complete when it was linked to CVRES-Happy module because it’s a user interface or dashboard that connects a person to a machine, system, or device. In addition, the CVRES-Analysis module must be linked to the main CVRES as well because it’s a module to record experimental data and analysis. The case study for this experiment as shown in Fig.5.
Barrel shaft
Critical position
Fig. 5. A case study on power transmission of shaft cam
T. Channarong et al. / Procedia Manufacturing 30 (2019) 677–684 T. Channarong and B. Suthep / Procedia Manufacturing 00 (2018) 000–000
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4. Experiment protocol As already discussed, finding appropriate dimensions by virtual rotating simulation on the barrel shaft are selected for the experiment protocol since motion simulation activity involved a lot of interaction and real time. It is decided to limit the experimentation elementary task to give it through a critical position of a barrel shaft. The experiment is tested by 10 participant users. Every participant is expected to repeat the task 10 times which means a barrel shaft is moved forward and reward rotated 10 times by using a haptic arm. Therefore, the participants repeats 110 times within the physical environment of the haptic arm with force-feedback combined with 3D glasses on 2D wall screen. The barrel shaft was rotated about 2 seconds per each time on the physical environment configuration by using a haptic arm as shown in Fig 6.
Forward direction
Reward direction
Fig. 6. Rotation direction for experiment protocol
This experiment context aims to analyze and find the appropriate dimension of internal and external arc radius for the barrel shaft design. The user is supported to analyze the possibility for the barrel shaft to rotate continuously without blocking or having other unwanted behavior. Simultaneously, the balance and stability of manipulation is evaluated in the experiment by using of basic sensors of the CVRES. Factors affecting the expected movement for a barrel shaft are the dimension of internal and external arc radius as well as the distance between the two arcs. Therefore, the distance between internal and external are related to the two arcs independently issued from the CAD fillet command. For the experiment considered the dimension of a barrel shaft through 11 types of radius values defining the distance between both arcs and the result of the most accurate dimension will be simulated the tools trajectory in the next step. The various dimensions that affect for a barrel cam rotation as shown in Table 1. Table 1. The various dimensions that affect for a barrel cam rotation The main dimensions
Internal arc
External arc Width of slot
Type
Internal arc (Radius)
Width of slot
External arc (Radius)
1 2 3 4 5 6 7 8 9 10 11
10.00 ± 0.021 11.00 ± 0.021 12.00 ± 0.021 13.00 ± 0.021 14.00 ± 0.021 15.00 ± 0.021 16.00 ± 0.021 17.00 ± 0.021 18.00 ± 0.021 19.00 ± 0.021 20.00 ± 0.021
20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000
30.00 ± 0.021 31.00 ± 0.021 32.00 ± 0.021 33.00 ± 0.021 34.00 ± 0.021 35.00 ± 0.021 36.00 ± 0.021 37.00± 0.021 38.00 ± 0.021 39.00 ± 0.021 40.00 ± 0.021
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5. Manufacturing preparation In this context, it’s 3 D model preparation to perform for manufacturing process associated with machine selection and tools management. A barrel shaft type 6 was selected for manufacturing preparation and it was imported into CAM software to simulate the tool trajectory. In this case, focused on the use of 5 axis CNC lathe and milling machines because it is popular in the industries for parts manufacturing. The CNC vertical mill 5 axis and lathe with live tooling machines were selected to experiment protocol through the stock to leave 0.0 mm, axial depth 0 . 5 mm, and groove depth 10 mm for this experiment. The geometrical characteristics of the cutting part for each tool consists of cutting length 35 mm, number of tool teeth 4 teeth’s, and cutting tool material was coated carbide. The manufacturing preparation for this research, is 4 x radial roughing machining by groove machining of the barrel shaft only because it’s apposition that requires high accuracy of dimensioning and tolerancing. The tool trajectory simulation on CAM software, each machine and tool has been replicated repeatedly for 10 times by 10 participants. Participants performed with caution and precision control throughout the experiment. The variables that must be controlled precisely for the experiment include: kind of machining, cutting speed, speed frequency, feed rate, and tool feed rate. Moreover, the key issues to consider for manufacturing preparation process are speed and precision by proceeding under the conditions in Table 2. Table 2. The cutting condition of CNC vertical mill 5 axis and lathe with live tooling machines Side mills
Frequency
Tooth feed rate (fz)
Feed rate (vf)
Tool feed rate (fz x Z)
100 m/min.
Ø 14 mm
2,274 rpm
0.5 mm/tooth
4,547 mm/min.
2 mm/rev.
100 m/min.
Ø 16 mm
1,989 rpm
0.5 mm/tooth
3,979 mm/min.
2 mm/rev.
Ø 18 mm
1,768 rpm
0.5 mm/tooth
3,537 mm/min.
2 mm/rev.
Index
Kind of machining
Cutting speed
1
4 x Radial roughing
2
4 x Radial roughing
3
4 x Radial roughing
100 m/min.
6. Experimental results The experimental results are about the tool trajectory simulation by using CNC vertical mill 5 axis and lathe with live tooling machines were reported the average values of each machine and tool. The experimental results are all the same execution time such as total time, approach, and machining times. The results summarized of the experiment were presented in Table 3. Table 3. The average values of the tool trajectory simulation for CNC vertical mill 5 axis and lathe with live tooling machines Total time:
05Minutes 27Seconds
04Minutes 17Seconds
05Minutes 35Seconds
Work:
05Minutes 23Seconds
04Minutes 13Seconds
05Minutes 20Seconds
Rapid:
00Minutes 03Seconds
00Minutes 03Seconds
00Minutes 15Seconds
Approach:
00Minutes 01Seconds
00Minutes 01Seconds
00Minutes 01Seconds
Machining:
05Minutes 24Seconds
04Minutes 14Seconds
05Minutes 25Seconds
Work:
05Minutes 23Seconds
04Minutes 13Seconds
05Minutes 20Seconds
Rapid:
00Minutes 01Seconds
00Minutes 01Seconds
00Minutes 05Seconds
Retract:
00Minutes 00Seconds
00Minutes 00Seconds
00Minutes 00Seconds
7. Conclusion Virtual reality barrel shaft design and assembly planning accompany with CAM has been presented tool trajectory simulation of CNC machines are experimented with VR method. This method can help a design engineer to understand functionality of the part assembly conception clearly. Furthermore, the machine operator can learn and understand the bill of material accurately and precisely.
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T. Channarong et al. / Procedia Manufacturing 30 (2019) 677–684 T. Channarong and B. Suthep / Procedia Manufacturing 00 (2018) 000–000
Acknowledgement I would like to thank the Princess of Naradhiwas University and Office of the Higher Education Commission, Thai Ministry of Education for granting me a scholarship and providing me with the facilities to complete this research. References [1] Jocelyn Parong and Richard E. Mayer, Learning Science in Immersive Virtual Reality, Journal of Educational Psychology, (2018) 1-13. [2] Dhalmahapatra K., Das S., Kalbande S., and Maiti J., Virtual Prototype based Simulator for EOT Crane, Industrial Safety Management, (2017) 11-26. [3] Colin R. Smith et al., Efficient Computation of Cartilage Contact Pressures within Dynamic Simulations of Movement, Computer Methods in Biomechanics and Biomedical Engineering: Imaging & Visualization, (2018) 491-498. [4] Jixiang Yang et al., Kinematics Model and Trajectory Interpolation Algorithm for CNC Turning of Non-circular Profiles, Precision Engineer, (2018) 212-221. [5] Xiaojun Chen, Pengjie Sun, and Denghong Liao, A Patient-specific Haptic Drilling Simulator based on Virtual Reality for Dental Implant Surgery, International Journal of Computer Assisted Radiology and Surgery. (2018) 1861-1870. [6] Delvin Grant and BenjaminYeo, A Global Perspective on Tech Investment, Financing, and ICT on Manufacturing and Service Industry Performance, International Journal of Information Management, (2018) 130-145. [7] Andrey Kutin et al., Simulation Modeling of Assembly Processes in Digital Manufacturing, Procedia CIRP, (2018) 470-475. [8] Justyna Trojanowska et al., A Methodology of Improvement of Manufacturing Productivity Through Increasing Operational Efficiency of the Production Process, Advances Manufacturing, (2017) 23-32. [9] Xingyu Li et al., Real-Time Teaming of Multiple Reconfigurable Manufacturing Systems, CIRP Annals. (2018) 437-440. [10] Shuo-Fang Liu et al., A Study of Perception Using Mobile Device for Multi-haptic Feedback, Human Interface and the Management of Information, (2018) 218-226. [11] Jakub Wojciechowski and Olaf Ciszak, Spatial Adjusting of the Industrial Robot Program with Matrix Codes, Advances Manufacturing, (2017) 521-531. [12] Lingyan Peng BDS et al., Accuracy and Reproducibility of Virtual Edentulous Casts Created by Laboratory Impression Scan Protocols, The Journal of Prosthetic Dentistry, (2018) 389-395.
ScienceDirect ScienceDirect
Available Availableonline onlineatatwww.sciencedirect.com www.sciencedirect.com Procedia Manufacturing 00 (2018) 000–000 Procedia Manufacturing 00 (2018) 000–000
ScienceDirect ScienceDirect
www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia
Procedia Manufacturing 30 (2019) 677–684 Procedia Manufacturing 00 (2017) 000–000 www.elsevier.com/locate/procedia
14th Global Congress on Manufacturing and Management (GCMM-2018) 14th Global Congress on Manufacturing and Management (GCMM-2018)
Virtual reality barrel shaft design and assembly planning accompany Virtual reality barrel shaft design assembly planning accompany with and CAM Manufacturing Engineering Society International Conference 2017, MESIC 2017, 28-30 June witha*CAM T. Channarong , and B. Suthepb Vigo (Pontevedra), Spain b a* T.2017, Channarong , and B. Suthep
Industrial Engineering Department, Princess of Naradhiwas University, 99 Khok Kian Muang Narathiwat, Narathiwat 96000, Thailand a Industrial Engineering Department, Princess of Naradhiwas 99 Khok Muang Narathiwat, 96000, Thailand Production Engineering Department, King Mongkut’s UniversityUniversity, of Technology NorthKian Bangkok, 1518 PracharatNarathiwat 1 Road, Wongsawang Bangsue b Bangkok Thailand Production Engineering Department, King Mongkut’s University of 10800, Technology North Bangkok, 1518 Pracharat 1 Road, Wongsawang Bangsue Bangkok 10800, Thailand a
Costing models for capacity optimization in Industry 4.0: Trade-off between used capacity and operational efficiency
b
Abstract A. Santanaa, P. Afonsoa,*, A. Zaninb, R. Wernkeb Abstract a University of Minho, Portugal This paper proposes the virtual reality concept to design and 4800-058 assemblyGuimarães, planning for a barrel shaft. The shaft model was created on b Unochapecó, 89809-000 Chapecó, SC, Brazil This proposes the virtual concept to design and assembly planning for aasbarrel shaft.method. The shaft model was created on CAMpaper and digital verification forreality effective functional design together with simulation traditional Presently, virtual reality CAM and digital verificationtofor effective functional design together with simulation as traditional Presently, virtualinreality technology is sophisticated mechanical components design and assembly animation which canmethod. help a design engineer order technology is sophisticated to mechanical components design optimization. and assemblyCollaborative animation which canenvironment help a design engineer order to show possibility alternative assembly planning and achieve virtual system wasinused to to show assembly planning and achieve optimization. Collaborative virtual environment system was used to create thepossibility assemblyalternative plan animation. Abstract create the assembly plan animation. © 2018 The Authors. Published by Elsevier Ltd. © 2018 2019 The Authors. by Elsevier Ltd. Under the concept of "Industry productionlicense processes will be pushed to be increasingly interconnected, © The Authors. Published by Elsevier Ltd. ) This is an open accessPublished article under the4.0", CC BY-NC-ND (https://creativecommons.org/licenses/by-nc-nd/4.0/ This is an open access article under the CC BY-NC-ND licensemuch (https://creativecommons.org/licenses/by-nc-nd/4.0/) information based on a real time basis and, necessarily, more this context, optimization This is an and openpeer-review access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/ ) and Selection under responsibility of the scientific committee efficient. of the 14thInGlobal Congresscapacity on Manufacturing Selection and peer-review under responsibility of the scientific committee of the 14th Global Congress on Manufacturing and goes beyond the traditional aimresponsibility of capacity maximization, for organization’s profitability and value. Selection and(GCMM-2018). peer-review under of the scientificcontributing committee ofalso the 14th Global Congress on Manufacturing and Management Management (GCMM-2018). Management Indeed, lean(GCMM-2018). management and continuous improvement approaches suggest capacity optimization instead of
Keywords: VirtualThe Reality Design Assembly Planning, Barrel Shaft, Digitalmodels Verification, Optimization, maximization. study ofand capacity optimization and costing is an importantCAM research topic that deserves Keywords: Virtual Reality Design Assembly Planning, Barrel perspectives. Shaft, Digital Verification, Optimization, contributions from both the and practical and theoretical This paper presents CAM and discusses a mathematical model for capacity management based on different costing models (ABC and TDABC). A generic model has been *Corresponding Author E. mail address: [email protected] developed andAuthor it wasE.used to analyze idle capacity and to design strategies towards the maximization of organization’s *Corresponding mail address: [email protected] value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity 1. Introduction optimization might hide operational inefficiency. 1. Introduction © 2017 The Authors. Published by Elsevier B.V. Currently, the virtual reality (VR) technology is used extensively by covers almost all professions [1]. Due to the Peer-review under of (VR) the scientific committee of the Manufacturing Engineering Society International Conference Currently, theresponsibility virtual reality used extensively by potential covers almost all professions [1]. Due to the flexibility of the VR application suchtechnology as systems is provide an enormous for enhancing the 3 D visualization 2017. flexibility the VR application as systems provide an enormous for enhancing the 3 D visualization linked withof interaction device. Itsuch includes the open dynamic engine potential (ODE) and collision detection module [2]. linked with interaction device. It includesmedical, the open dynamic engine and (ODE) and fields. collision module Especially, application in engineering, military, education another Thisdetection introduction aims[2]. to Keywords: Costits Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency Especially, in engineering, medical, education and another fields. Thisindustries introduction aims to present alsoits theapplication context of the research respect to the military, mechanical parts design for manufacturing in Thailand. present contextexpects of the research to the mechanical parts design for manufacturing in Thailand. Becausealso thisthe research to buildrespect new knowledge for the benefit of Thailand’s economyindustries which relevant to the Because this research expects to build newtoknowledge for theprocess. benefit of which relevant to the design process and simulate throughout manufacturing It Thailand’s focuses oneconomy the movement simulation of 1. Introduction design process and simulate throughout to manufacturing process. It focuses on the movement simulation of The cost of idle capacity is a fundamental information for companies and their management of extreme importance 2351-9789 2018 The Authors. Published by Elsevier in modern©production systems. In general, it isLtd. defined as unused capacity or production potential and can be measured This is an open access under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) 2351-9789 © 2018 Thearticle Authors. Published by Elsevier Ltd. in several ways: tons of production, available hours of manufacturing, etc. The management of the idle capacity Selection and peer-review under responsibility of the scientific committee of the 14th Global Congress on Manufacturing and Management This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) * Paulo Afonso. Tel.: +351 253responsibility 510 761; fax: of +351 604 741 (GCMM-2018). Selection and peer-review under the 253 scientific committee of the 14th Global Congress on Manufacturing and Management E-mail address: [email protected] (GCMM-2018).
2351-9789 Published by Elsevier B.V. Ltd. 2351-9789©©2017 2019The TheAuthors. Authors. Published by Elsevier Peer-review underaccess responsibility the scientific committee oflicense the Manufacturing Engineering Society International Conference 2017. This is an open article of under the CC BY-NC-ND (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection and peer-review under responsibility of the scientific committee of the 14th Global Congress on Manufacturing and Management (GCMM-2018). 10.1016/j.promfg.2019.02.063
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mechanical components in VR environment [3]. Furthermore, to simulate the tools trajectory for CNC milling and turning machines are performed by 4-5D contouring through computer aided manufacturing (CAM) software [4]. The experimental methods are expected to determine design and simulate tasks through collaborative virtual reality environment system (CVRES). The experiment is used to validate and compare with the performance of CVRES to optimize the design and movement simulation tasks. The different various of CVRES respect to arrangements of the engines/equipment as well as applications. A CVRES consist of several VR modules and the modules must be connected to interaction device to support an expected task. In this context to achieve assess barrel shaft transmissions for motion simulation experiment. The CVRES consist of analysis module and inserted with the preliminary sensors: stopwatch, orientation, and instability sensor. In this research has selected the most appropriate virtual environment for this context using a haptic arm with force-feedback combined with 3D glasses on 2D wall screen [5]. By the time that the design process ends, the next step is analytical process which the most appropriate tools selection and trajectories for CNC milling & turning machines. The main goal is not to compare a few specific environments but to the comparison itself. Incidentally, the complexity of design or global innovative design are challenges for designers and engineers. But the main objective is to offer them a correct design and simulation framework as well as the application of the tools technologies to suit the context. Nowadays, the tools used (CAD/CAM/CAE/CNC) for manufacturing industries are widely popular for designer, engineers, and manufacturing experts [6]. Meanwhile, the VR technology in high performance platform but they often do not know which platform or environment will be the most effective for the expected tasks. If our research is successful as expected, we may have use VR technology to develop capabilities design and manufacturing. Particularly, for the manufacturing of mechanical parts in designing activities such as assembly and simulation [7]. 2. Research Methodology The goal of this research was expected to build high level assessment technique to assess motion performance and to compare barrel shaft in different dimensions. We propose a process to measure objective of criteria using basic level measures. The VR session is instrumented with primary sensors that can be reported automatically. This research proposes to achieve VR environment that suits the context of design, assembly and simulation activities. The general structure and procedure of research methodology for this context includes: system and implementation methodology to reach the desired goals which are shown in Fig. 1.
The general structure and procedure of research methodology The desired goals
System and implementation methodology
Manufacturing Preparation
CVRES
Implementation
User
Senses (Hand & Eye)
Machines Selection
Task or context
Movement Simulation
- Lathe with live tooling -Vertical mill 5 axis
System or Software
CVE
Tools trajectory simulation
Environment
Physical Environments
Database analysis
Tool management
Fig. 1. The general structure and procedure of research methodology
- Generic tools database - Personal tools database
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2.1 System and implementation methodology The CVRES module consists of four core components; the user or participant, interacts with computer operating systems, the task or context, is the activity related to the design phase and will be tested in this research for motion tasks, the system or software which is called a Collaborative Virtual Reality Environment System (CVES), the environment, defines the used hardware with various combinations of interaction and visualization which it has defined physical environments: a haptic arm with force-feedback combined with 3D glasses on 2D wall screen as shown in the Fig 2.
Fig. 2. A haptic arm interface modeled haption Virtuose 6D35-45
2.2 Manufacturing preparation method This section contains information about the manufacturing process and operations. Manufacturing are processes defined to produce a product or sub-product [8]. The manufacturing process determines the required operational resources, setup time, production time, and cost calculation [9]. In this context, machines and tools are selected to produce virtually a barrel shaft manufacturing process with a good quality, consistently servicing the parts. The manufacturing preparation method for this experiment has been created using the Top Solid v 7.11 program. The main context in this section is the selection of machinery to use for manufacturing process. They are CNC machines; CNC lathe and CNC vertical milling. The CNC lathe machine can perform together with milling operation. It is able to work as milling, drilling, and grinding tasks as shown in the Fig. 3. The 5 axes CNC Vertical mill machine is shown in the Fig 4.
Fig. 3. Virtual CNC Lathe machine
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Fig. 4. CNC 5-axis milling machine
2. System overview System overview for the general purpose of 3D visualization and interaction devices manipulation. The CVRES consists of several modules but for this context selected the following ones: a communication server, a configuration editor, a 3D viewer enabling virtual reality usage, an analysis module, and haptic connector. The server dispatches events between the various modules. Moreover, CVRES is a multi-agent-based system dedicated to collaborating within a virtual/augmented environment. A socket-based communication system is employed to ensure the communication between agents. Every agent oversees a behavior of the global virtual environment. The various CVRES modules used in our experiment. In the current experiment, the expected sub-behaviors correspond to five modules;
CVRES-Editor module
The CVRES-Editor module enables to import and to export the object format. Moreover, in this module we can modify the scene (colors) and provide access to any state value of the scene. “It is necessary to import” a STL or OBJ file format into CVRES Editor before working with the collaboration virtual reality environment software.
CVRES-Viewer module
CVRES-Viewer oversees creating the 3D visualization and sending it to the final display which can be holographic, stereoscopic or a simple 2D screen. CVRES Viewer opens 3D windows which can display diverse imported 3D objects by “wave front OBJect” file format, it is simply referred to as the (OBJ) file format. Concerning the 3D models imported for this research, all elements were imported and exported in OBJ data formats by using CAD software. The OBJ file format can be imported directly into CVRES Viewer module which generates the scene and 3D models.
CVRES-ODE module
The CVRES-ODE module is especially important for simulating dynamics articulated rigid body, which will be the invisible model for collision detection and force-feedback. It is particularly good for simulating moving objects in changeable virtual reality environments because it is quite fast, robust, and stable. Collision detection prevents part interpenetration for the user regarding how to move position and orientation of the parts to finish the operation.
CVRES-Happy module
CVRES-Happy is a module to take in charge the connection with a haptic arm. It can survey the position of the human operator’s hand and it drives the arm actuators to apply a force feed-back, if feedback is activated [10] during
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virtual assembly and simulate tasks. The haptic arm available in our laboratory, is the Virtuose 6D35-45 which is composed of two main articulated segments fixed on a rotating base.
CVRES-Analysis module
CVRES-Analysis module has several basic sensors which can be selected and adjusted from the CVRES-editor. This research selected two basic sensors to evaluate the way users performing the movement simulation tasks during our experiment. These sensors are the duration and instability sensors. The duration sensor measures the duration of the experiments. The duration is the interval of time between the event launching the analysis and the event stopped the analysis. No special attributes are expected to define this sensor since it is a global sensor associated with the whole analysis. The instability sensor intends to measure the evolution of a position during a lap of time. Instability sensor evaluates the gesture instability. The position of two points in a frame defined by a transformation matrix defining the position of the manipulated object is continuously analyzed. The trajectory of these points is linearized by small intervals of time and the sensor compares the real path length of the point respecting to the linearized trajectory interval per interval. The ratio gives an idea of the oscillation of the trajectory around a more efficient straight path. It depicts the gesture shivers. This ratio is recorded by the analysis module for every conducted experiment. A task can be defined, processed and repeated several times as a record file provides the raw result of these basic sensors. 3. CAD for VR environment preparation Nowadays, 3D geometric models is created using CAD software by relying on the expertise of designers, engineers, and manufacturing experts. In general, CAD software is efficient in import and export in various file formats such as Stereo Lithography (STL), Standard for Exchange of Product model data (STEP AP203), Virtual Reality Modeling Language (VRML), and so on [10-12]. In this research, the 3D models are individually exported into STL file formats and transformed into CVRES-Editor module. For this reason, the translation mode is a 3D model of the VR environment is thus, once the initial process for working on CVRES-Viewer module. Furthermore, to reopen the STL file merge nodes and to export the meshes into OBJ files format. Besides, choosing to use OBJ file format because it can compress the file well and an intermediary step is performed through the STL to OBJ conversion. Particularly, a barrel shaft mechanism movement simulation able to interact with the CVRES-ODE module. For this research, the kinematics constraints of barrel shaft was rebuilt from scratch directly of the CVRES-ODE module. The operation will be more complete when it was linked to CVRES-Happy module because it’s a user interface or dashboard that connects a person to a machine, system, or device. In addition, the CVRES-Analysis module must be linked to the main CVRES as well because it’s a module to record experimental data and analysis. The case study for this experiment as shown in Fig.5.
Barrel shaft
Critical position
Fig. 5. A case study on power transmission of shaft cam
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4. Experiment protocol As already discussed, finding appropriate dimensions by virtual rotating simulation on the barrel shaft are selected for the experiment protocol since motion simulation activity involved a lot of interaction and real time. It is decided to limit the experimentation elementary task to give it through a critical position of a barrel shaft. The experiment is tested by 10 participant users. Every participant is expected to repeat the task 10 times which means a barrel shaft is moved forward and reward rotated 10 times by using a haptic arm. Therefore, the participants repeats 110 times within the physical environment of the haptic arm with force-feedback combined with 3D glasses on 2D wall screen. The barrel shaft was rotated about 2 seconds per each time on the physical environment configuration by using a haptic arm as shown in Fig 6.
Forward direction
Reward direction
Fig. 6. Rotation direction for experiment protocol
This experiment context aims to analyze and find the appropriate dimension of internal and external arc radius for the barrel shaft design. The user is supported to analyze the possibility for the barrel shaft to rotate continuously without blocking or having other unwanted behavior. Simultaneously, the balance and stability of manipulation is evaluated in the experiment by using of basic sensors of the CVRES. Factors affecting the expected movement for a barrel shaft are the dimension of internal and external arc radius as well as the distance between the two arcs. Therefore, the distance between internal and external are related to the two arcs independently issued from the CAD fillet command. For the experiment considered the dimension of a barrel shaft through 11 types of radius values defining the distance between both arcs and the result of the most accurate dimension will be simulated the tools trajectory in the next step. The various dimensions that affect for a barrel cam rotation as shown in Table 1. Table 1. The various dimensions that affect for a barrel cam rotation The main dimensions
Internal arc
External arc Width of slot
Type
Internal arc (Radius)
Width of slot
External arc (Radius)
1 2 3 4 5 6 7 8 9 10 11
10.00 ± 0.021 11.00 ± 0.021 12.00 ± 0.021 13.00 ± 0.021 14.00 ± 0.021 15.00 ± 0.021 16.00 ± 0.021 17.00 ± 0.021 18.00 ± 0.021 19.00 ± 0.021 20.00 ± 0.021
20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000 20.00 ± 0.000
30.00 ± 0.021 31.00 ± 0.021 32.00 ± 0.021 33.00 ± 0.021 34.00 ± 0.021 35.00 ± 0.021 36.00 ± 0.021 37.00± 0.021 38.00 ± 0.021 39.00 ± 0.021 40.00 ± 0.021
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5. Manufacturing preparation In this context, it’s 3 D model preparation to perform for manufacturing process associated with machine selection and tools management. A barrel shaft type 6 was selected for manufacturing preparation and it was imported into CAM software to simulate the tool trajectory. In this case, focused on the use of 5 axis CNC lathe and milling machines because it is popular in the industries for parts manufacturing. The CNC vertical mill 5 axis and lathe with live tooling machines were selected to experiment protocol through the stock to leave 0.0 mm, axial depth 0 . 5 mm, and groove depth 10 mm for this experiment. The geometrical characteristics of the cutting part for each tool consists of cutting length 35 mm, number of tool teeth 4 teeth’s, and cutting tool material was coated carbide. The manufacturing preparation for this research, is 4 x radial roughing machining by groove machining of the barrel shaft only because it’s apposition that requires high accuracy of dimensioning and tolerancing. The tool trajectory simulation on CAM software, each machine and tool has been replicated repeatedly for 10 times by 10 participants. Participants performed with caution and precision control throughout the experiment. The variables that must be controlled precisely for the experiment include: kind of machining, cutting speed, speed frequency, feed rate, and tool feed rate. Moreover, the key issues to consider for manufacturing preparation process are speed and precision by proceeding under the conditions in Table 2. Table 2. The cutting condition of CNC vertical mill 5 axis and lathe with live tooling machines Side mills
Frequency
Tooth feed rate (fz)
Feed rate (vf)
Tool feed rate (fz x Z)
100 m/min.
Ø 14 mm
2,274 rpm
0.5 mm/tooth
4,547 mm/min.
2 mm/rev.
100 m/min.
Ø 16 mm
1,989 rpm
0.5 mm/tooth
3,979 mm/min.
2 mm/rev.
Ø 18 mm
1,768 rpm
0.5 mm/tooth
3,537 mm/min.
2 mm/rev.
Index
Kind of machining
Cutting speed
1
4 x Radial roughing
2
4 x Radial roughing
3
4 x Radial roughing
100 m/min.
6. Experimental results The experimental results are about the tool trajectory simulation by using CNC vertical mill 5 axis and lathe with live tooling machines were reported the average values of each machine and tool. The experimental results are all the same execution time such as total time, approach, and machining times. The results summarized of the experiment were presented in Table 3. Table 3. The average values of the tool trajectory simulation for CNC vertical mill 5 axis and lathe with live tooling machines Total time:
05Minutes 27Seconds
04Minutes 17Seconds
05Minutes 35Seconds
Work:
05Minutes 23Seconds
04Minutes 13Seconds
05Minutes 20Seconds
Rapid:
00Minutes 03Seconds
00Minutes 03Seconds
00Minutes 15Seconds
Approach:
00Minutes 01Seconds
00Minutes 01Seconds
00Minutes 01Seconds
Machining:
05Minutes 24Seconds
04Minutes 14Seconds
05Minutes 25Seconds
Work:
05Minutes 23Seconds
04Minutes 13Seconds
05Minutes 20Seconds
Rapid:
00Minutes 01Seconds
00Minutes 01Seconds
00Minutes 05Seconds
Retract:
00Minutes 00Seconds
00Minutes 00Seconds
00Minutes 00Seconds
7. Conclusion Virtual reality barrel shaft design and assembly planning accompany with CAM has been presented tool trajectory simulation of CNC machines are experimented with VR method. This method can help a design engineer to understand functionality of the part assembly conception clearly. Furthermore, the machine operator can learn and understand the bill of material accurately and precisely.
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Acknowledgement I would like to thank the Princess of Naradhiwas University and Office of the Higher Education Commission, Thai Ministry of Education for granting me a scholarship and providing me with the facilities to complete this research. References [1] Jocelyn Parong and Richard E. Mayer, Learning Science in Immersive Virtual Reality, Journal of Educational Psychology, (2018) 1-13. [2] Dhalmahapatra K., Das S., Kalbande S., and Maiti J., Virtual Prototype based Simulator for EOT Crane, Industrial Safety Management, (2017) 11-26. [3] Colin R. Smith et al., Efficient Computation of Cartilage Contact Pressures within Dynamic Simulations of Movement, Computer Methods in Biomechanics and Biomedical Engineering: Imaging & Visualization, (2018) 491-498. [4] Jixiang Yang et al., Kinematics Model and Trajectory Interpolation Algorithm for CNC Turning of Non-circular Profiles, Precision Engineer, (2018) 212-221. [5] Xiaojun Chen, Pengjie Sun, and Denghong Liao, A Patient-specific Haptic Drilling Simulator based on Virtual Reality for Dental Implant Surgery, International Journal of Computer Assisted Radiology and Surgery. (2018) 1861-1870. [6] Delvin Grant and BenjaminYeo, A Global Perspective on Tech Investment, Financing, and ICT on Manufacturing and Service Industry Performance, International Journal of Information Management, (2018) 130-145. [7] Andrey Kutin et al., Simulation Modeling of Assembly Processes in Digital Manufacturing, Procedia CIRP, (2018) 470-475. [8] Justyna Trojanowska et al., A Methodology of Improvement of Manufacturing Productivity Through Increasing Operational Efficiency of the Production Process, Advances Manufacturing, (2017) 23-32. [9] Xingyu Li et al., Real-Time Teaming of Multiple Reconfigurable Manufacturing Systems, CIRP Annals. (2018) 437-440. [10] Shuo-Fang Liu et al., A Study of Perception Using Mobile Device for Multi-haptic Feedback, Human Interface and the Management of Information, (2018) 218-226. [11] Jakub Wojciechowski and Olaf Ciszak, Spatial Adjusting of the Industrial Robot Program with Matrix Codes, Advances Manufacturing, (2017) 521-531. [12] Lingyan Peng BDS et al., Accuracy and Reproducibility of Virtual Edentulous Casts Created by Laboratory Impression Scan Protocols, The Journal of Prosthetic Dentistry, (2018) 389-395.