A Novel Rule-Based Method for Individualized Spot Welding Sequence Optimization With Respect to Geometrical Quality

Tabar, Roham Sadeghi; Wärmefjord, Kristina; Söderberg, Rikard; Lindkvist, Lars

doi:10.1115/1.4044254

Cited by 16 publications

(8 citation statements)

References 23 publications

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“…Accurately capture and process the in situ spatial information from a controller Improve the accuracy of voxel models of the workpiece-in-process [18][19][20][21][22] Process planning Ensure the accuracy of positioning, tool path planning, and efficiency for blend features Precise micro process planning for generating machining instructions [23][24][25][26] Process monitoring High cost and high probability of damage to UPM system Improve product quality under the dynamic change of the machining condition [27][28][29][30] Vibration control Call for multi-physics modeling techniques as well as real-time controlling.…”

Section: Voxel Modelingmentioning

confidence: 99%

“…Apparently, employing finite element method simulation for exhaustive searching for the holistic optimum of tolerancing in process planning is both costly in computing time and infeasible in the digital twin model [40]. Tabar et al [25] introduced a rule-based model to initiate the genetic algorithm for spot weld sequencing in three automotive sheet metal assemblies for further evaluation, which could be used in enabling the digital twins. Nevertheless, it is still challenging to build computational efficient algorithms for the digital twins-based process planning model, as the parameters and their relationships involved are complicated.…”

Section: Digital Twins-based Process Planningmentioning

confidence: 99%

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Digital Twins-Based Smart Design and Control of Ultra-Precision Machining: A Review

Leng

2021

Symmetry

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Ultra-Precision Machining (UPM) is a kind of highly accurate processing technology developed to satisfy the manufacturing requirements of high-end cutting-edge products including nuclear energy producers, very large-scale integrated circuits, lasers, and aircraft. The information asymmetry phenomenon widely exists in the design and control of ultra-precision machining. It may lead to inconsistency between the designed performance and operational performance of the UPM equipment on stiffness, thermal stability, and motion accuracy, which result from its design, manufacturing, and control, and determine the form accuracy and surface roughness of machined parts. The performance of the UPM equipment should be improved continuously. It is still challenging to realize the real-time and self-adaptive control, in which building a high-fidelity and computationally efficient digital twin is a valuable solution. Nevertheless, the incorporation of the digital twin technology into the UPM design and control remains vague and sometimes contradictory. Based on a literature search in the Google Scholar database, the critical issues in the UPM design and control, and how to use the digital twin technologies to promote it, are reviewed. Firstly, the digital twins-based UPM design, including bearings module design, spindle-drive module design, stage system module design, servo module design, and clamping module design, are reviewed. Secondly, the digital twins-based UPM control studies, including voxel modeling, process planning, process monitoring, vibration control, and quality prediction, are reviewed. The key enabling technologies and research directions of digital twins-based design and control are discussed to deal with the information asymmetry phenomenon in UPM.

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Section: Voxel Modelingmentioning

confidence: 99%

Section: Digital Twins-based Process Planningmentioning

confidence: 99%

Digital Twins-Based Smart Design and Control of Ultra-Precision Machining: A Review

Leng

2021

Symmetry

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“…The variation simulation techniques have become more sophisticated by considering the effects of heat [43], non-linearity of materials [44], and welding sequences [45,46]. Several commercial programs have been developed to implement these techniques in CAD models for practical uses.…”

Section: Compliant Variation Simulationsmentioning

confidence: 99%

Integrated Tolerance and Fixture Layout Design for Compliant Sheet Metal Assemblies

et al. 2021

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Part tolerances and fixture layouts are two pivotal factors in the geometrical quality of a compliant assembly. The independent design and optimization of these factors for compliant assemblies have been thoroughly studied. However, this paper presents the dependency of these factors and, consequently, the demand for an integrated design of them. A method is developed in order to address this issue by utilizing compliant variation simulation tools and evolutionary optimization algorithms. Thereby, integrated and non-integrated optimization of the tolerances and fixture layouts are conducted for an industrial sample case. The objective of this optimization is defined as minimizing the production cost while fulfilling the geometrical requirements. The results evidence the superiority of the integrated approach to the non-integrated in terms of the production cost and geometrical quality of the assemblies.

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“…Huang et al have applied a genetic algorithm (GA) to minimize the displacements after spot welding, with a specific sequence [7]. Other studies have also shown the applicability and effectivity of the GA on the welding and clamping sequence problem [8][9][10]. Different evolutionary algorithms, namely, ant colony and particle swarm optimization, have been evaluated using the FEA approach.…”

Section: Spot Welding Sequence Optimizationmentioning

confidence: 99%

A new surrogate model–based method for individualized spot welding sequence optimization with respect to geometrical quality

Tabar

Wärmefjord

Söderberg

2019

Int J Adv Manuf Technol

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In an individualized shee metal assembly line, form and dimensional variation of the in-going parts and different disturbances from the assembly process result in the final geometrical deviations. Securing the final geometrical requirements in the sheet metal assemblies is of importance for achieving aesthetic and functional quality. Spot welding sequence is one of the influential contributors to the final geometrical deviation. Evaluating spot welding sequences to retrieve lower geometrical deviations is computationally expensive. In a geometry assurance digital twin, where assembly parameters are set to reach an optimal geometrical outcome, a limited time is available for performing this computation. Building a surrogate model based on the physical experiment data for each assembly is time-consuming. Performing heuristic search algorithms, together with the FEM simulation, requires extensive evaluations times. In this paper, a neural network approach is introduced for building surrogate models of the individual assemblies. The surrogate model builds the relationship between the spot welding sequence and geometrical deviation. The approach results in a drastic reduction in evaluation time, up to 90%, compared to the genetic algorithm, while reaching a geometrical deviation with marginal error from the global optimum after welding in a sequence.

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A Novel Rule-Based Method for Individualized Spot Welding Sequence Optimization With Respect to Geometrical Quality

Cited by 16 publications

References 23 publications

Digital Twins-Based Smart Design and Control of Ultra-Precision Machining: A Review

Digital Twins-Based Smart Design and Control of Ultra-Precision Machining: A Review

Integrated Tolerance and Fixture Layout Design for Compliant Sheet Metal Assemblies

A new surrogate model–based method for individualized spot welding sequence optimization with respect to geometrical quality

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