CISM COURSES AND LECTURES

Series Editors:

The Rectors of CISM Sandor Kaliszky - Budapest

Mahir Sayir - Zurich Wilhelm Schneider - Wien

The Secretary General of CISM Giovanni Bianchi - Milan

Executive Editor Carlo Tasso - Udine

The series presents lecture notes, monographs, edited works and proceedings in the field of Mechanics, Engineering, Computer Science

and Applied Mathematics. Purpose of the series is to make known in the international scientific and technical community results obtained in some of the activities

organized by CISM, the International Centre for Mechanical Sciences.

INTERNATIONAL CENTRE FOR MECHANICAL SCIENCES

COURSES AND LECTURES -No. 372

ADVANCED MANUFACTURING SYSTEMS AND TECHNOLOGY

EDITED BY

E. KULJANIC UNIVERSITY OF UDINE

~ Springer-Verlag Wien GmbH

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or similar means, and storage in data banks.

© 1996 by Springer-Verlag Wien

Originally published by Springer-Verlag Wien New York in 1996

In order to make this volume available as economically and as

rapidly as possible the authors' typescripts have been

reproduced in their original forms. This method unfortunately

has its typographical limitations but it is hoped that they in no

way distract the reader.

ISBN 978-3-211-82808-3 ISBN 978-3-7091-2678-3 (eBook)

DOI 10.1007/978-3-7091-2678-3

MATERIALS SCIENCE AND THE SCIENCE OF MANUFACTURING- INCREASING PRODUCTIVITY

MAKING PRODUCTS MORE RELIABLE AND LESS EXPENSIVE

ORGANIZERS

University of Udine - Faculty of Engineering - Department of Electrical, Managerial and Mechanical Engineering - Italy

Centre International des Sciences Mecaniques, CISM - Udine - Italy University of Rijeka - Technical Faculty - Croatia

CONFERENCE VENUE

CISM - PALAZZO DEL TORSO Piazza Garibaldi, 18 - UDINE

PREFACE

The International Conference on Advanced Manufacturing Systems

and Technology - AMST is held every third year. The First International

Conference- AMST'87 was held in Opatija (Croatia) in October 1987. The

Second International Conference - AMST'90 was held in Trento (Italy) in

June 1990 and the Third International Conference - AMST'93 was held in

Udine (Italy) inApril1993.

The Fourth International Conference on Advanced Manufacturing

Systems and Technology - AMST'96 aims at presenting trend and an up-to­

date information on the latest developments - research results and industrial

experience in the field of machining of conventional and advanced materials

CIM non-conventional machining processes forming and quality assurance

thus providing an international forum for a beneficial exchange of ideas, and

furthering a favorable cooperation between research and industry.

E. Kuljanic

HONOUR COMMITTEE

S. CECOTTI, President of Giunta Regione Autonoma Friuli-Venezia Giulia M. STRASSOLDO D1 GRAFFEMBERGO, Rector of the University of Udine G. BIANCHI, General Secretary of CISM S. DEL GIUDICE, Dean of the Faculty of Engineering, University of Udine J. BRNIC, Dean of the Technical Faculty, University of Rijeka C. MELZI, President of the Associazione Industriali della Provincia di Udine

SCIENTIFIC COMMITTEE

E. KULJANIC (Chairman), University of Udine, Italy N. ALBERTI, University of Palermo, Italy A. ALTO, Polytechnic of Bari, Italy P. BARIANI, University of Padova, lta,ly G. BIANCHI, CISM, Udine, Italy A. BUGINI, University of Brescia, Italy R. CEBALO, University of Zagreb, Croatia G. CHRISSOLOURIS, University of Patras, Greece M.F. DE VRIES, University of Wisconsin Madison, U.S.A. R. IPPOLITO, Polytechnic of Torino, Italy F. JOV ANE, Polytechnic of Milano, Italy I. KAT A VIC, University of Rijeka, Croatia H.J.J. KALS, University of Twente, The Netherlands F. KLOCKE, T.H. Aachen, Germany W. KONIG, T.H. Aachen, Germany F. LE MAITRE, Ecole Nationale Superieure de Mechanique, France E. LENZ, Technion, Israel R. LEVI, Polytechnic of Torino, Italy B. LINDSTROM, Royal Institute of Technology, Sweden V. MATKOVIC, Croatian Academy of Science and Arts, Croatia J.A. Me GEOUGH, University of Edimburg, UK M.E. MERCHANT, lAMS, Ohio, U.S.A. G.F. MICHELETTI, Polytechic of Torino, Italy B. MILCIC, INAS, Zagreb, Croatia S. NOTO LA DIEGA, University of Palermo, Italy J. PEKLENIK,University of Ljubljana, Slovenia H. SCHULZ, T.H. Darmstadt, Germany N.P. SUH, MIT, Mass., U.S.A. H.K. TONSHOFF, University of Hannover, Germany B.F. von TURKOVICH, University of Vermont, U.S.A. K. UEHARA, University of Toyo, Japan A. VILLA, Polytechnic of Torino, Italy

ORGANIZING COMMITEE

E. KULJANIC (Chairman) M. NICOLICH (Secretary) C. BANDERA, F. COSMI, F. DE BONA, M. GIOV AGNONI, F. MIANI, M. PEZZETIA, P. PASCOLO, M. REINI, A. STROZZI, G. CUKOR

SPONSORSHIP ORGANIZATIONS

Presidente della Giunta Regione Autonoma Friuli-Venezia Giulia Croatian Academy of Science and Arts, Zagreb C.U.M. Community of Mediterranean Universities

SUPPORTING ORGANIZATIONS

Comitato per Ia promozione degli studi tecnico-scientifici University of Udine Pietro Rosa T.B.M. s.r.l., Maniago

CONTENTS

Page Preface

Trends in Manufacturing World Trends in the Engineering of the Technological and Human Resources of Manufacturing by M. E. Merchant ..................................................................................................... 1

Advanced Machining of Titanium- and Nickel-Based Alloys by F. Klocke, W. Konig and K. Gerschwiler .............................................................. 7

Machinability Testing in the 21st Century-Integrated Machinability Testing Concept by E. Kuljanic ............................................................................................................ 23

High-Speed Machining in Die and Mold Manufacturing by H. Schulz .............................................................................................................. 37

Forming Processes Design Oriented to Prevent Ductile Fractures by N. Alberti and F. Micari ...................................................................................... 47

Wire Drawing Process Modellization: Main Results and Implications by D. Antonelli, A. Bray, F. Franceschini, D. Romano, A. Zompz and R. Levi ........ 63

New Methods of Measuring Planning for Coordinate Measuring Machines by H.K. Tons hoff, C. Bode and G. Masan ................................................................ 77

Role and Influence of Ecodesign on New Products Conception, Manufacturing and Assembly by G.F. Micheletti ..................................................................................................... 85

Part I - Machining Processes Prediction of Forces, Torque and Power in Face Milling Operations by E.J.A. Armarego and J. Wang ............................................................................. 97

Evaluation of Thrust Force and Cutting Torque in Reaming by R. Narimani and P. Mathew .............................................................................. 107

Wear of Ceramic Tools When Working Nickel Based Alloys by S. Lo Casto, E. Lo Valvo, M. Piacentini and V.F. Ruisi ................................... 115

Titanium Alloy Turbine Blades Milling with PCD Cutter by M. Beltrame, E. Kuljanic, M. Fioretti and F. Miani .......................................... 121

Transfer Function of Cutting Process Based on Output Input Energy Relations by S. Dolinsek ......................................................................................................... 129

A Neural Network Architecture for Tool Wear Detection Through Digital Camera Observations by C. Giardini, E. Ceretti and G. Maccarini .......................................................... 137

Influence of Pre-Drilling on Life of Taps by G.M. Lo Nostro, G. E. D 'Errico and M. Bruno ................................................ 145

Influences of New Cutting Fluids on The Tapping Process by J. Kopac, M. Sokovic and K. Mijanovic ............................................................. 153

Intensification of Drilling Process by A. Koziarski and B. W. Kruszynski ..................................................................... 161

Milling Steel With Coated Cermet Inserts by G.E. D'Errico and E. Guglielmi ....................................................................... 169

Safe Machining of Magnesium by N. Tomac, K. Tr;mnessen and F.O. Rasch ......................................................... 177

Fast Sensor Systems for the Monitoring of Workpiece and Tool in Grinding by H.K. Tons hoff, B. Karpuschewski and C. Regent ........................................ ...... 185

Truing of Vitrified-Bond Cbn Grinding Wheels for High-Speed Operations by M. Jakobuss and J.A. Webster ........................................................................... 193

Forces in Gear Grinding - Theoretical and Experimental Approach by B. W. Kruszynski and S. Midera ......................................................................... 201

Part II - Optimization and Processes Planning Optimum Cutting Condition Determination for Precision Turning by V. Ostafiev and D. Ostafiev ................................................................................ 209

Computer Integrated and Optimised Turning by R. Mesquita, E. Henriques, P.S. Ferreira and P. Pinto ................................... 213

Multi-Criteria Optimization in Multi-Pass Turning by G. Cukor and E. Kuljanic .................................................................................. 221

On-Line Control Techniques: Optimisation of Tool Substitution Interval by E. Ceretti, C. Giardini and G. Maccarini .......................................................... 229

Step-Oriented Data and Knowledge Sharing for Concurrent CAD/CAPP Integration by W. Eversheim and P. Y. Jiang ............................................................................ 237

Automatic Clamping Selection in Process Planning Using Tolerance Verification Algorithms by L.M. Galantucci, L. Tricarico and A. Dersha ................................................... 245

Optimization of Technological Process by Experimental Design by N. Sakic and N. Stefanic ..................................................................................... 253

Robust Design of Automated Guided Vehicles System in an FMS by A. Plaia, A. Lombardo and G. LoNigro ........................................................... 259

Constraint Programming Approach for the Optimization of Turning Cutting Parameters by L.M. Galantucci, R. Spina and L. Tricarico ...................................................... 267

Application of Customer/Supplier Relations on Decentralized Short Term Production Planning and Control in Automotive Industries by K. Mertins, R. Albrecht, 0. Bahns, S. Beck and B. La Pierre ........................... 275

Artificial Intelligence Support System for Manufacturing Planning and Control by D. Benic ............................................................................................................. 283

Computer Aided Manufacturing Systems Planning by T. Mikac ...... ................. ....... ....... ....... ........ ......... ........ . .................................... 291

Linear Programming Model for Optimal Exploitation of Space by N. Stefanic and N. Sakic ..................................................................................... 299

A Family of Discrete Event Models for Flow Line Production by M. Lucertini, F. Nicolo, W Ukovich and A. Villa ............................................. .305

Part III - Forming Characterization of Ti and Ni Alloys for Hot Forging: Setting-Up of an Experimental Procedure by P.F. Bariani, G.A. Berti, L. D'Angelo and R. Guggia ...................................... 313

An Analysis of Female Superplastic Forming Processes by A. F orcellese, F. Gabrielli and A. Mancini ........................................................ 321

Overview of Proestamp: An Integrated System for the Design, Optimization and Performance Evaluation of Deep Drawing Tools by R.M.S.O. Baptista and P.M. C. Custodio ........................................................... 331

Layered Tool Structure for Improved Flexibility of Metal Forming Processes by T. Pepelnjak, Z. Kampus and K. Kuzman ......................................................... 339

Physical Simulation Using Model Material for the Investigation of Hot-Forging Operations by P.F. Bariani, G.A. Berti, L. D'Angelo and R. Meneghello ............................... 347

Texture Evolution During Forming of the Ag 835 Alloy for Coin Production by L. Francesconi, A. Grottesi, R. Montanari and V. Sergi ................................... 355

Determination of the Heat Transfer Coefficient in the Die-Billet Zone for Nonisotherrnal Upset Forging Conditions by P.F. Bariani, G.A. Berti, L. D'Angelo and R. Guggia ...................................... 363

Determining the Components Forces by Rotary Drawing of Conical Parts by D.B. Lazarevic, V. Stoiljkovic and M.R. Radovanovic ....................................... 371

Determination of the Optimal Parameters of Castin a Copper Wire by the Application of Neural Networks by V. Stoiljkovic, M. Arsenovic, Lj. Stoiljkovic and N. Stojanovic ........................... 379

Flexible Machining System for Profile and Wire Cold Rolling by M. Jurkovic ........................................................................................................ 387

Part IV - Flexible Machining Systems Influence of Tool Clamping Interface in High Performance Machining by E. Lenz and J. Rotberg ...................................................................................... 395

A Methodology to Improve FMS Saturation by M. Nicolich, P. Persi, R. Pesenti and W. Ukovich ............................................ .405

Autonomous Decentralized System and JIT Production by T. Odanaka, T. Shohdohji and S. Kitakubo ...................................................... .413

Selection of Machine Tool Concept for Machining of Extruded Aluminium Profiles by E. Rr;sby and K. Trpnnessen ............................................................................... 421

Machine Location Problems in Flexible Manufacturing Systems by M. Braglia ......................................................................................................... 429

Work-In-Process Evaluation in Job-Shop and Flexible Manufacturing Systems: Modelling and Empirical Testing by A. De Toni and A. Meneghetti ............................................................................ 437

On the Application of Simulation and Off-Line Programming Techniques in Manufacturing by R. Baldazo, M.L. Alvarez, A. Burgos and S. Plaza ........................................... 445

Selection Criteria for Georeferencing Databases in Industrial Plant Monitoring Applications by C. Pascolo and P. Pascolo ........................................................ ; ....................... 453

Octree Modelling in Automated Assembly Planning by F. Failli and G. Dini .......................................................................................... 463

Technology ·subsystem in the Information System of Industry by N. Majdandzic, S. Sebastijanovic, R. Lujic and G. Simunovic .......................... .471

Integration CAD/CAM/CAE System for Production All Terrain Vehicle Manufactured with Composite Materials by G. Vrtanoski, Lj. Dudeski and V. Dukovski ...................................................... .479

Part V - Non Conventional Machining Microfabrication at the Elettra Synchrotron Radiation Facility by F.. De Bona, M. Matteucci, J. Mohr, F.J. Pantenburg and S. Zelenika ............ .487

Thermal Response Analysis of Laser Cutting Austenitic Stainless Steel by J. Grum and D. Zuljan ...................................................................................... 495

Optimization of Laser Beam Cutting Parameters by R. Cebalo and A. Stoic ....................................................................................... 503

Low-Voltage Electrodischarge Machining -Mechanism of Pulses Generation by /.A. Chemyr, G.N. Mescheriakov and 0. V. Shapochka ..................................... 511

Numerical Model for the Determination of Machining Parameters in Laser Assisted Machining by F. Buscaglia, A. Motta and M. Poli ................................................................... 519

Deep Small Hole Drilling with EDM by M. Znidarsic and M. Junkar .............................................................................. 527

Influence of Current Density on Surface Finish and Production Rate in Hot Machining of Austenitic Manganese Steel by S. Trajkovski ...................................................................................................... 535

Experimental Study of Efficiency and Quality in Abrasive Water Jet Cutting of Glass by E. Capello, M. Monno and Q. Semeraro ........................................................... 543

Technological Aspects of Laser Cutting of Sheet Metals by M.R. Radovanovic and D.B. Lazarevic ............ , ................................................ 551

Microfabricated Silicon Biocapsule for Immunoisolation of Pancreatic Islets by M. Ferrari, W.H. Chu, T.A. Desai and J. Tu .................................................... 559

Mathematical Model for Establishing the Influence of an External Magnetic Field on Characteristics Parameters at ECM by C. Opran and M. Lungu .................................................................................... 569

Part VI - Robotics and Control Computer Aided Climbing Robot Application for Life-Cycle Engineering in Shipbuilding by R. Muhlhiiusser, H. Muller and G. Seliger ........................................................ 577

The Use of Three-Dimensional Finite Element Analysis in Optimising Processing Sequence of Synergic Mig Welding for Robotic Welding System by M. Dassisti, L.M. Galantucci and A. Caruso .................................................... 585

Monitoring Critical Points in Robot Operations with an Artificial Vision System by M. Lanzetta and G. Tantussi ............................................................................. 593

CAM for Robotic Filament Winding by L. Carrino, M. Landolfi, G. Moroni and G. DiVita .......................................... 601

An Automatic Sample Changer for Nuclear Activation Analysis by F. Cosmi, V.F. Romano and L.F. Bellido ......................................................... 609

On the Simplification of the Mathematical Model of a Delay Element by A. Beghi, A. Lepschy and U. Viaro .................................................................... 617

Model Reduction Based on Selected Measures of the Output Equation Error by W. Krajewski, A. Lepschy and U. Viaro ............................................................ 625

Control of Constrained Dynamic Production Networks by F. Bianchini, F. Rinaldi and W. Ukovich .......................................................... 635

Part VII - Measuring A Coordinate Measuring Machine Approach to Evaluate Process Capabilities of Rapid Prototyping Techniques by R. Meneghello, L. De Chiffre and A. Sacilotto ................................................... 645

An Integrated Approach to Error Detection and Correction on the Curves and Surfaces of Machined Parts by A. Sahay ............................................................................................................. 653

A New On-Line Roughness Control in Finish Turning Operation by C. Borsellino, E. Lo Valvo, M. Piacentini and V.F. Ruisi ................................. 661

Application of the Contisure System for Optimizing Contouring Accuracy of CNC Milling Machine by Z. Pandilov, V. Dukovski and Lj. Dudeski ......................................................... 669

Functional Dimensioning and Tolerancing: A Strong Catalyst for Concurrent Engineering Implementation by S. Tornincasa, D. Romano and L. Settineri ....................................................... 677

Methodology and Software for Presenting the Model of Mechanical Part by Assembling Primitives by V. Gecevska and V. Pavlovski ............................................................................ 685

Design of Hydraulic Pumps with Plastic Material Gears by A. De Filippi, S. Favro and G. Crippa .............................................................. 693

Correlating Grinded Tool Wear with Cutting Forces and Surface Roughness by R. Cebalo and T. Udiljak ................................................................................... 701

Part VIII - Materials and Mechanics Tube Bulging with Nearly "Limitless" Strain by J. Tirosh, A. Neuberger and A. Shirizly ............................................................. 709

Improving the Formability of Steel by Cyclic Heat Treatment by B. Smoljan .......................................................................................................... 717

Mechanical Analysis of a Solid Circular Plate Simply Supported Along two Antipodal Edge Arcs and Loaded by a Central Force by A. Strozzi ............................................................................................................ 723

Machinability Evaluation of Leaded and Unleaded Brasses: A Contribution Towards the Specification of Ecological Alloys by R.M.D. Mesquita and P.A.S. Lourenro ............................................................. 131

Square Ring Compression: Numerical Simulation and Experimental Tests by L. Filice, L. Frantini, F. Micari and V.F. Ruisi .................................... , ........... 739

New Advanced Ceramics for Cutting Steel by M. Burelli, S. Maschio and E. Lucchini ............................................................. 747

New Generation Arc Cathodic PVD Coatings "Platit" for Cutting Tools, Punchs and Dies by D. Franchi, F. Rabezzana, H. Curtins and R. Menegon .................................. 753

Fine Blanking of Steel anq Nonferrous Plates by J. Caloska and J. Lazarev ........................ ~ ......................................................... 761

Remelting Surface Hardening of Nodular Iron by J. Grum and R. Sturm ....................................................................................... 769

Machining with Linear Cutting Edge by P. Manka ........................................................................................................... 777

Part IX · Quality Model-Based Quality Control Loop at the Example of Turning-Processes by 0. Sawodny and G. Goch .................................................................................. 785

The Effect of Process Evolution on Capability Study by A. Passannanti and P. Valenti ........................................................................... 793

Measuring Quality Related Costs by J. Mrsa and B. Smoljan ..................................................................................... 801

Certification of Quality Assurance Systems by G. Meden ........................................................................................................... 807

Quality Assurance Using Information Technological Interlinking of Subprocesses in Forming Technology by D.lwanczyk ....................................................................................................... 815

Analysing Quality Assurance and Manufacturing Strategies in Order to Raise Product Quality by C. Basnet, L. Foulds and I. Mezgar .............. _. ................................................... 823

Development of Expert System for Fault Detection in Metal Forming by P. Cosic ............................................................................................................. 831

Managerial Issues for Design of Experiments by F. Galetto ................................................................•.......................................... 839

Split-Plot Design: A Robust Analysis by R. Guseo ............................................................................................................ 849

Robustness of Canonical Analysis for Some Multiresponse Dependent Experiments by C. Mortarino ...................................................................................................... 857

Authors Index .................................................................................................................... 865