CISM COURSESAND LECTURES

Series Editors:

The Reetars of CISM Manuel Gqrcia Velarde - Madrid

Mahir Sayir - Zurich Wilhelm Schneider - Wien

The Secretary General of CISM Bernhard Sehreller - Padua

Former Secretary General of CISM Giovanni Bianchi - Milan

Executive Editor Carlo Tasso- Udine

This series presents lecture notes, monographs, edited works and proceedings in the field of the 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

COURSESAND LECTURES - No. 437

AMST'02

ADVANCED MANUFACTURING SYSTEMSAND TECHNOLOGY

PROCEEDINGS OF THE SIXTHINTERNATIONAL CONFERENCE

EDITEDBY

ELSO KULIANIC UNIVERSITY OF UDINE

~ Springer-Verlag Wien GmbH

This book was printed with the contribution of Consorzio Universitario del Friuli and Regione Friuli Venezia Giulia

This volume contains 547 illustrations

This work is subjected to copyright. All rights are reserved,

wheter the whole or part of the material is concemed specifically those of translation, reprinting, re-use of illustrations,

broadcasting, reproduction by photocopying machine or similar means, and storage in data banks.

© 2002 by Springer-Verlag Wien Originally published by Springer-Verlag Wien New York in 2002

Softcover reprint of the hardcover 1st edition 2002

SPIN 10882242

In order to make this volume available as economically and as rapidly as possible the authors' typescripts have been

reproduced in the original forms. This method unfortunately has its typographicallimitations but it is hoped that they in no way

distract the reader.

ISBN 978-3-7091-2557-1 ISBN 978-3-7091-2555-7 (eBook)

DOI 10.1007/978-3-7091-2555-7

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 Seiences Mecaniques, CISM - Udine - Italy University of Rijeka- College of Engineering- Croatia

CONFERENCE VENUE

University of Udine - PALAZZO ANTONINI Via Tarcisio Petracco 8, Udine, Italy

PREFACE

Manufacturing a product is not difficult, the difficulty consists in manufacturing a product of high quality, at a low cost and rapidly.

Progress in materials and manufacturing sciences and technology, as weil as in intelli­gent machining systems, promotes an increase in productivity and a decrease of costs and pro­duction time without compromising the reliability of the products. In the new global and national condition the competitiveness of products depends in turn on their quality, which is becoming increasingly relevant.

The International Conference on Advanced Manufacturing Systems and Technology -AMST is held every third year. The First International Conference on Advanced Manufacturing Systemsand Technology AMST'87 was held in Opatija (Croatia) in October I987. The Second International Conference on Advanced Manufacturing Systems and Technology AMST'90 was held in Trento (Italy) in June I990. The Third, Fourth an Fifth Conferences on Advanced Manufacturing Systemsand Technology were alt held in Udine (Italy) asfollows: AMST'93 in April I993, AMST'96 in September I996 and AMST'99 in June 1999.

The Sixth International Conference on Advanced Manufacturing Systems and Technology - AMST'02, which was held in Udine in June 2002, aimed at presenting up-to-date information on the latest developments - research results and experience - in the field of machining of conventional and advanced materials, machine tools and flexible manufacturing systems, forming, nonconventional processes, robotics, measurement and control, quality, design and ecodesign, rapid prototyping, rapid taofing and manufacturing, materials and mechanics, thus providing an international forum for a beneficial exchange of ideas and fur­thering a favourable cooperation between research and industry.

Elso Kuljanic

HONOUR COMMITTEE

R. TONDO, President of Giunta Regione Autonoma Friuli - Venezia Giulia M. STRASSOLDO DI GRAFFEMBERGO, President of Provincia di Udine F. HONSELL, Rector of the University of Udine D. RUKAVINA, Rector of the University of Rijeka A. STELLA, Dean of the Faculty of Engineering, University of Udine S. CECOTTI, Mayor of Udine A. VALDUGA, President of the Associazione Industriali della Provincia di Udine G. FRAU, President of Consorzio Universitario del Friuli B. SCHREFLER, General Secretary of CISM G. BENEDETTI, Danieli & C. M. FANTONI, Fantoni Spa A. PITTINI, Gruppo Pittini R. SNAIDERO, Snaidero R. Spa

SCIENTIFIC COMMITTEE

E. KULJANIC, (Chairman), University of Udine, ltaly N. ALBERT!, University of Palermo, ltaly P. BARIANI, University of Padova, ltaly A. BUGINI, University of Bergamo, ltaly R. CEBALO, University of Zagreb, Croatia G. CHRISSOLOURIS, University of Patras, Greece B. FRANKOVIC, University of Rijeka, Croatia M.F. DE VRIES, University of Wisconsin Madison, U.S.A. R. IPPOLITO, Polytechnic of Torino, ltaly F. JOVANE, Polytechnic of Milano, ltaly I. KATAVIC, University of Rijeka, Croatia H.J.J. KALS, University of Twente, The Netherlands F. KLOCKE, T.H. Aachen, Germany F. LE MAITRE, Ecole Nationale Supeneurede Mechanique, France E. LENZ, Technion, Israel R. LEVI, Polytechnic of Torino, ltaly B. LINDSTROM, Royal Institute of Technology, Sweden G. MARINSEK, Centro Ricerche Fiat, ltaly J.A. Mc GEOUGH, University of Edimburg, UK M.E. MERCHANT, IAMS, Ohio, U.S.A. G .F.MICHELETTI, Polytechnic of Torino, ltaly B. MILCIC, INAS, Zagreb, Croatia T. NAKAGAWA, University OfTokyo, Japan S. NOTO LA DIEGA, University of Palermo, ltaly J. PEKLENIK, University of Ljubljana, Slovenia H. SCHULZ, T.H. Darmstadt, Germany

G. SPUR, T.U. Berlin, 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. UEDA, Kobe University, Japan A. VILLA, Polytechnic of Torino, Italy

ORGANIZING COMMITEE

E. KULJANIC (Chairman) F. MIANI (Secretary) G. BIANCHI, C. BANDERA, F. DE BONA, S. FILIPPI, A. GASPARETTO, M. GIOVAGNONI, S. MIANI, G. CUKOR, M. SORTINO

SUPPORTING ORGANIZATIONS

Giunta Regione Autonoma Friuli - Venezia Giulia, Provincia di Udine, Comune di Udine, University of Udine, Consorzio Universitario del Friuli, Danieli & C., Fantoni Spa, Gruppo Pittini, Snaidero R. Spa, Fondazione Cassa di Risparmio di Udine e Pordenone, Comitato per la promozione degli studi tecnico scientifici, Centro Convegni ed Accoglienza, Pietro Rosa T.B.M., FAMUP, ONRIFO Office of Naval Research International Field Office, US Navy.

CONTENTS

Preface

Trends in Mannfactoring

The Dynamic Cluster Structures: a New Manufacturing Paradigm for Production of High-Tech Product

by J. Peklenik

Recent Development and Trends in Tool Condition Monitaring by E. Kuljanic and M. Sortino

Comprehensive Simulation of Manufacturing Processes by H. K. Toenshoff, M. Clausen and K. Tracht

Knowledge Management- an Essential Contribution to Company's Success by H. Schutz

Industrial Experiments - Theory and Practice by R. Levi and D. Romano

Disassembly for Recycling, Maintenance and Remanufacturing: State of the Art and Perspectives

by M. Santochi, G. Dini and F. Failli

Analysis of some Innovative and Flexible Sheet Forming Processes by N. Alberti and F. Micari

Machining Processes

lmprovement of the Surface Texture Quality of Milled Dies and Molds by A. Moisan, M. Boujelbene, B. Brenier and A. Fahre

Machining Abrasion-resistant Hard-facings with PCBN Tools by E. J. Brookes, R. D. James, C. Shutt and C. J. Taylor

Page

1

15

37

49

61

73

91

105

113

Machining Process lmprovement by Practical Tests in Shop Floor by N. L. Coppini and E. A. Baptista 121

Crankshaft Manufacturing on Machining Centres- Turn-miHing and Deep Hole Drilling by K. Wienert and H. Loebbe 129

A Contribution to the Strain-Hardening Process Analysis of Hardened Steel During High­Speed Machining

by S. Dolinsek and S. Ekinovic 137

Tool Flank Wear Prediction Using the Force-Time Measurement in Tuming by G. Cukor and E. Kuljanic 143

Metal Matrix Composites - MMC - Turning: Comparison of Tool Materials by C. Borsellino, S. Lo Casto, E. Lo Valvo and V. F. Ruisi 151

Application of a Rotating Dynamometer for Cutting Force Measurement in Milling by E. Kuljanic, M. Sortino and F. Miani 159

Simulation of Chip Formation in an Orthogonal Cutting Process Using FEM by G. Giorleo, R. Teti, A. Langella, D. D'Addona and U. Prisco 167

Study of Macro and Micro Quality Determinants of Pieces Obtained from Optimized Drilling Process

by A. Lima and M. Vieira Jr 179

Experimental Test for Tool Life Prediction in Turning by M. Nicolich 185

Technological Models Based on Grinding Wheel and Workpiece Characteristic in the Grinding Process of MMCs

by A. Di Ilio and A. Paoletti 193

Optimisation of Process Conditions Using "Experiments with Mixtures" by N. Sakic, V. Panic and I. Dubravec 203

Selection of Optimal Cutting Condition in Computer Aided Machining by Genetic Algorithms

by V. Gecevska, V. Pavloski 209

Machine Tools and Flexible Mannfactoring Systems

An Alternative Approach to Elasto-kinematic ModeHing of Machine Tool Structures by H. K. Tonshoff, S. Rehling and K. Tracht 215

Reliability and Availability of Complex Production Systems by H.P. Wiendahl and M. Hegenscheidt 225

Modem Tendencies in Rotary Transfer Machines by E. Gentili, C. Giardini, R. Pasquino and P. Quinzani 233

The Machine Tool's Next Step: Step NC by M. Weck and J. Wolf 241

An Automated System for Dimensional Control Based on Computer Vision by C. Borsellino, E. Lo Valvo and V.F. Ruisi 249

Stiffness of CNC Machine Tool Feed Drives by Z. Pandilov and V. Dukovski 259

A Set of Criteria for Supply Chain Design by A. Villa 267

Applying of Typical Technological Operations in the Single Production by G. Simunovic, N. Majdandzic, K. Simunovic and R. Lujic 275

Process Planning Application and Internet Connection by P. Cosic , D. Sever and S. Milinovic 283

E-business Requires Simulation of Logistic Processes by W. Sihn, T.D. Graupner, U. Mussbach-Winter and H. Wiedenmann 291

Tool Path Optimization by High Speed Machining by J. Kopac and T. Rohlek 299

Uncertainty Analysis and Optimization of a FMS by Experimental Design Applied to

Simulation by B. Palumbo, F. Caiazzo and V. Sergi 307

Computer Aided Determination of Feasibility of Work Operation on Machines in Flexible Manufacturing Systems

by /. Pahole 317

An Integrated Tool for Geometrical Reconstruction of Functional Surfaces by D. Comelli, G. Concheri and R. Meneghello 321

Forming

Cost-efficient Manufacturing by Employing Incremental Forming Processes by P. Groche, M. Jöckel, C. Rachor and T. Rathmann

The Use of a Neural Network in Predicting the Mechanical Properties of Low Carbon Steels After Hot Rolling

by F. Caiazzo, F. Memola Capece Minutolo, R. Pasquino and V. Sergi

FEM Model Computing Large Deformation in Metal Sheet Forming by High PowerBeam

by G. Casalino, G. De Astis and A. D. Ludovico

Investigation of the Effects ofThermal and Mechanical Fatigue of Dies in Hot Forging Through a New Simulative Laboratory Test

by G. Berti, S. Bruschi, S. Masiero, M. Monti and M. Zimmitti

Flow ModeHing of AA 6082 Aluminium Alloy by C. Bruni, A. Forcellese and F. Gabrielli

Simulation of Welding Conditions in Porthole Die Extrusion by L. Donati and L. Tomesani

Towards a General Quality Indicator for Adaptive FEM Simulation of Sheet Forming Processes

by M. Strano and L. Carrino

The Main Principles of Forming Integral Panels used in Modem Shipbuilding Industry

by R. Markovina

329

337

347

357

367

375

383

393

The Main Principles of Using and Forming Integral Panels in Modem Shipbuilding lndustry

by R. Markovina

Design of the Tube Roll Forming Process Through an Heuristic Algorithm by G. Celano, A. Costa, S. Fichera and L. Fratini

Design Issues for Micro-formed Sheet Metal Components by D. Antonelli and P. Chiabert

Finite Elastoplasticity in Plane Strain Cold Rolling Problem by J. Brnic, M. Canadija and G. Turkalj

Nonconventional Processes

Bumishing Versus Grinding For Automotive Parts

401

409

417

425

by L. Luca, I. Marinescu and S. Neagu-Ventzel 433

Evaluation of Warpage of Injection Moulded Parts Using RE and FEM Approaches by L.M. Galantucci, G. Percoco, R. Spina and L. Tricarico 441

Analyzing the Warpage in the Injection Molding Using SLS Tool Inserts by J. Gabor, J. Kovacs 449

Orbital Electrochemical Machining of Electrodischarge Machined Surfaces by Z. Sadollah Bamerni and H. El-Hofy 457

Design of Low Expansion Composites with Reduced Process lnduced U ncertainties

by F De Bona, A. Gambitta and A. Soma' 465

Analysis of High Power C02 Dual Beam Laser Welding by E. Capello,· P. Chiarello, E. Piccione and B. Previtali 473

Filament Winding: an Integrated Simulation Environment for Automated Cell Programming

by A. Anglani, F Nucci and A. Spagnolo 481

Methods for Welding Quality Improvements by D. Pavletic 491

Radial Segregation of Workpiece in Barrel Finishing by A. Boschetto and F. Veniali 499

Shape Machining of Aerospace Composite Components Using Non-Traditional Abrasive

Waterjet Cutting Processes by X. Zheng, L. Chen, E. Siores, P. Steele and P. Crothers 507

Comparative Studies of Brush Elettrodischarge Machining with Electrodes of

Alloy Steel and Tungsten by S. Spadlo 515

Robotics, Measurement and Control

Measurement System for mN Forces by G. Manzoni and P. Miotti 525

Application of Statistical Process Control to Continuous Processes by G. Celano, A. Costa and S. Fichera 531

Design and Implementation of a Cartesian Robot by A. Gasparetto and G. Rosati 539

Design of a Robotic Wrist for Biomedical Applications by A. Gasparetto and A. Biason 545

Developement and Performance Assessment of a Laser Triangulation Scanner for

Digitizing Shoe Lasts by N. De Rossi, A. Rossi, A. Trevisani and V. Zanotto 553

Design and Development of a Vision Based Leather Trimming Machine by M. Lanzetta and G. Tantussi 561

Accuracy of a 3D Vision System for Inspection of Complex Geometry by S. Carmignato, E. Savio and L. De Chiffre 569

Autonomaus Agent System Using Dispatehing Rules in the Negotiation Protocol by L. Castelli, A. Nicola, R. Pesenti and W. Ukovich 577

Robustness Analysis of Frequency-Domain PI Controller Design Procedures by W. Krajewski, A. Lepschy, S. Miani and U. Viaro 585

A New Approach to the Use ofVibration Signals in Tool-Wear Monitaring in High Speed Metal Turning

by D. E. Dimla Snr and M. Sortino 593

Quality, Design and Ecodesign

Market Value of Recycled Material Mixes: a Key Parameter for Designing for Recycling by G. Berti, W.A. Knight and G. Lucchetta 601

Identification and Assessment of Non Conformity Parameters for Quality Cost Reduction by M. Boscolo and E. Padoano 609

Minimizing the Cost of Quality: an Innovative Sampling Plan by C. Giardini and G. Valentini 617

Optimizated Design of Notch Shapes for Microfabricated Compliant Mechanisms by E. Dalla Serra, F. De Bona and M. Munteanu 625

QFD And TM: a Pragmatical Approach by E. Gentili and F. Galetto 633

Datums Concepts by ASME and ISO standards by /. Cristofolini 641

Quality Decisions and ISO 9000: 2000 Principles by F. Galetto 649

Failure Scenario FMEA: Theoretical & Applicative Aspects by E. Locatelli, N. Valsecchi, G. Maccarini and A. Bugini 657

From Plastic Waste to Recycled-content End Products: the Chair lndustry Case by A. Meneghetti, G. Nardin and P. Simeoni 665

Quality Product Controls of Silicon Pixel Sensors for a High Energy Particle Physics Experiment

by G. Cabras, D. Cauz, D. Cobai, M. Cobal-Grassmann, B. De Lotto, C. Del Papa, H. Grassmann and L. Santi 673

Evaluation of DFX Tools in Ecodesign by M. Kljajin 679

Time Lag Error of Inventory in Inflation by J. Mrsa 687

Collaborative Design and Manufacturing of a Customizable Voice Prosthesis by G. Concheri, S. Filippi, R. Meneghello, C. Miani and D. Comelli 695

Analysis of Geometrical Distorsions of Spur Shafts due to Heat Treatments by L. D 'Angelo 705

Benchmarking of Attribute Two-level Sampling Schemes with Zero Acceptance Number by M. Dassisti 713

Rapid Prototyping, Tooling and Mannfactoring

Economic Evaluation of Alternatives for Microelectronics Lithography Processing by Z. Wang and W.A. Knight 723

Ceramic Components Built by Stereolithography by C. Esposito Corcione, A. Greco, A. Licciulli, M. Martena and A. Maffezzoli 731

CT-Based Reverse Engineering and Rapid Prototyping: Experiences in Different Application Domains

by C. Bandera, M. Felice and S. Filippi 741

Exploiting the Evaluation of RP Artifacts to Update Knowledge in Design Guidelines by C. Bandera, S. Filippi, F. Miani and G. Toneatto 749

A Contribution to the Analysis, Characterization and lmprovement of Surface Properties Generated by DMLS For RT

by M. Vezzani, A. 0. Andrisano, R. Groppetti, P. Onesti, A. Rossi and A. Scrivani 757

Laser Sintering of Sand and its Application in Rapid Tooling by X.H. Wang, J.Y.H. Fuh, Y.S. Wong and Y.X. Tang 771

Direct Laser Sintering of Cu-based Metallic Powder for Injection Moulding by H.H. Zhu, J. Y.H. Fuh and L. Lu

Materials and Mechanics

Molecular Dynamic Simulation of Nanoindentation of Silicon Carbide by Diamond Tip

779

by A. Noreyan, I. Marinescu and J. Amar 785

Influence of the Hot Isostatic Pressing on the Mechanical Behaviour of CVD-Coated Hardmetals

by M. Tolazzi, S. Kursawe and H. G. Sockel 793

Effect of Crystal Grientation on Surface Integrity by J. Prohaszka, J. Dobranszky, M. Horvath andA.G. Mamalis 801

Sintered Alloys Mechanical Properties Simulation with Cell Method by F. Cosmi 809

Some Properties of Nitrided Tool Steels by B. Smoljan 817

Fillet Stress Related to Non-uniformly Loaded Gear Tooth Geometry

~a~ro~ rn

Use of Ultrasound to Detect Internat Defects of Spheroidal Graphite Cast Iron Products by E. Ceretti, A. Attanasio and C. Giardini 833

Milling Tests of Austenitic Stainless Steel Without Nickel by L. Zaquini and P. Reusser 843

Uncertainty Management for Productive Process Control by M. Russo and D. Freguia 851

Micromilling - High Potential Technology for Micromechanical Parts by D. Spath, H. Tritschler, L. Bisehoffand W Schutz 859

FEM Analysis in a Machining Center by B. Cecchini, R. Pavan, D. Ruffati and M. Tellan, 865