Computer Aided Design of Manufacturing of Fasteners - Selection of the Best Production Chain

Abstract

Computer aided design of the manufacturing technology for the fasteners is presented the paper. The particular objectives of the work were twofold. The first objective is evaluation of applicability of various materials for fasteners. Analysis of different technological variants is the second objective of the research. In the material part, bainitic steels are considered as an alternative for the commonly used carbon-manganese steels. This is a continuation of [1,2]. Possibility of elimination of the heat treatment was evaluated. Main features of the new generation of bainitic steels are discussed briefly in the paper. Rheological models for all steels investigated in the project were developed. The models were implemented into the finite element code for simulations of drawing and multi stage forging. Simulations of various variants of manufacturing chain were performed and the best alternative was selected. Criteria for the selection composed dimensional accuracy and tool life. Industrial trials were performed for the selected cycle and the efficiency of this cycle was evaluated. Finally, the optimization task was formulated. However, solution of the optimization problem is costly at this stage and improvement of the efficiency of the formulation will be the objective of further research. References 1. Kuziak R., Skóra M., Węglarczyk S., Paćko M., Pietrzyk M., Computer aided design of the manufacturing chain for fasteners, Computer Methods in Materials Science, 11, 2011, 243-250. 2. Kuziak R., Pidvysots’kyy V., Węglarczyk S., Pietrzyk M., Bainitic steels as alternative for conventional carbon-manganese steels in manufacturing of fasteners - simulation of production chain, Computer Methods in Materials Science, 11, 2011, 443 – 462.

Application of Numerical and Physical Simulation to Design of the Best Manufacturing Technology for Fasteners

“…Beyond this, several auxiliary operations like phosphatizing or annealing are applied. The model developed in earlier publications [3,10] allows to simulate the whole chain. The properties and microstructural parameters are transferred from one process to the next one.…”

“…The general output from this research was twofold. Simulations of manufacturing chains are common [1][2][3][4][5][6][7][8][9][10] and optimization task for the whole chain based on metal forming can be formulated. On the other hand, connection of the optimization methods with simulation of manufacturing chain requires unacceptably long computing times.…”

“…The main task of the present work was considering the entire production chain. It is expected that this approach would provide possibility of accounting for relations between subsequent operations [8,9,10]. Primary tests have shown that optimization of the full manufacturing chain, although theoretically possible, would require extremely long computing times.…”

Computer Aided Design of Manufacturing of Anchors and Formulation of the Optimization Task for in Use Properties

“…Objectives of the present work are formulated with the above remarks in mind. Analysis of manufacturing of fasteners performed in [6] was extended and research is focused on anchors, which are used to carry heavy concrete loads. High quality and reliability is expected from the anchor-concrete joint.…”

A decision support methodology for embodiment design and process chain selection for hybrid manufacturing platforms

“…Skóra at el. [22] also studied forging technologies and implemented finite element simulations of tool wear and stress distribution into a process chain selection procedure. Hansen and Büttgenbach [23] present a process sequence analysis method for MEMS device based on process or material incompatibilities and manufacturing technology capabilities.…”