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Rapid Manufacturing of Vacuum Forming Components Utilising Reconfigurable Screw-Pin Tooling

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Rapid Manufacturing of Vacuum Forming Components Utilising Reconfigurable Screw-Pin Tooling Rapid Manufacturing of Vacuum Forming Components Utilising Reconfigurable Screw-Pin Tooling by Zhijian Wang, BEng, MSc Thesis Submitted to The University of Nottingham for the degree of Doctor of Philosophy August 2009 ABSTRACT Current market trends are moving from large quantity production towards small batch production and mass customization. This has led to the high demand for the flexibility and adaptability of manufacturing technology and systems. Several reconfigurable pin type tooling systems have been proposed and developed to satisfy such demands. However, these reconfigurable tooling systems still suffer from several drawbacks, including difficulties associated with positioning and locking the pins and problems of uneven “staircase” surface effects from relying on discrete finite size pins. The main focus of this research is on building a hybrid vacuum-forming machine system (HAVES) based on reconfigurable screw-pin tooling (SPT) as a test bed for understanding the processes involved in developing this technology and to examine the feasibility of implementing such technology in an industrial system. The SPT used is composed of identical screw pins, which are engaged with each other in an array pattern. By adjusting vertical displacement of the screw pins, a wide variety of component geometry can be formed. The adjustment methodology of the SPT is formulated mathematically in order to help construction of the SPT be parametrical thus enabling automatic CNC G-code generation. The HAVES test bed development involves full machine design and hardware and software integration. The hardware integration task included a CNC controller, drive motors, encoders, milling and screw adjustment heads, SPT, vacuum forming system. The software integration task involved the processing of three-dimensional CAD geometry to automatically generate post processed G codes in order to adjust the screw-pin to the required component geometry and subsequent surface machining for driving the final die geometry and minimize operator intervention. The completed HAVES test bed has been tested for accuracy, repeatability and functionalities with quality good results. An economic analysis has been also conducted to verify the economic feasibility of the HAVES test bed by comparing the cost of making vacuum forming components using a dedicated mould versus using the HAVES test bed. I ACKNOWLEDGEMENT The work described in this thesis was carried out at the Nottingham Innovative Manufacturing Research Centre and Rolls-Royce University Technology Centre at The University of Nottingham during the period of October 2005 to September 2008. My sincere thanks are due to my supervisor Professor Nabil Gindy, for his excellent guidance, patient supervision and financial support throughout this research. Without his support, this thesis would not have been possible. I greatly admire his enthusiasm, dedication, hard work and achievements in the field of advanced manufacturing technology. I would like to thank Mr Kevin Walker for his help on a day-to-day basis. Without his constant help and keen interest, it would have been impossible for me to carry out my project in a smooth manner and in good time. I would also like to thank Professor Detao Zheng, Professor Jian Sun and Professor Xin Chen for their support and encouragement during my PhD application and study. My thanks are extended to Mr Mark Daine and all other members of Nottingham Innovative Manufacturing Research Centre for their help and friendship. Finally, I am grateful to my family for their love, understanding, support and encouragement throughout the period of my studies. II PUBLICATION LIST 1. Z. Wang, Y. Wang, N. Gindy, “Design and Construction of Reconfigurable Screw-Pin Tooling for Vacuum Forming System”, Proceeding of The 18th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM 2008), 29th June to 2nd July, Sweden, 2008 2. Z. Wang, Y. Wang, N. Gindy, “An integrated vacuum forming system utilizing reconfigurable screw-pin tooling”, proceeding of the 4th International Conference on Responsive Manufacturing, 17-19 September, UK, 2007 3. Z. Wang, Y. Wang, N. Gindy, “A rapid NC programming based on data driving method”, Seventh National conference on Rapid design prototyping and manufacturing, pp. 123~128, 16 June, 2006 4. Y. Wang, Z. Wang, N. Gindy, “A method of machining fixture development based on concurrent engineering”, Seventh National conference on Rapid design prototyping and manufacturing, pp. 103~111, 16 June, 2006 5. Z. Wang, Y. Wang, N. Gindy, “Application of Knowledge Driven Automation Technology in Mould Tool Design”, Proceedings of the 3rd International Conference on Responsive Manufacturing (ICRM), pp.461-466, China, 2005 6. Y. Wang, Z. Wang, V. kancharla, N. Gindy, “A work support”, UK patent, GB2444910, applied by Rolls Royce plc, Publication date:25,June, 2008. 7. Y. Wang, Z. Wang, N. Gindy, “Collision-free machining fixture space design based on parametric tooling space for five-axis grinding”, International Journal of Advanced Manufacturing Technology, Volume 45, Issue 1, 2009, pp.1-7. 8. Y. Wang, Z. Wang, N. Gindy, “Interactive fixture and tool space design considering tool movement, machine and inspection for five-axis grinding“, Accepted by Proceedings of the Institution of Mechanical Engineers, Part B, Journal of Engineering Manufacture. 9. Y. Wang, J. Xie, Z. Wang, N. Gindy, “A parametric FEA system for fixturing of thin-walled cylindrical components", Journal of Materials Processing Technology, v 205, n 1-3,Aug 26, 2008, pp. 338-346. III TABLE OF CONTENTS ABSTRACT…………………………………………………………………… І ACKNOWLEDGEMENTS…………………………………………………… II LIST OF PAPERS……………………………………………………………. III TABLE OF CONTENTS…………………………………………………….. IIV LIST OF FIGURES…………………………………………………………… XI LIST OF TABLES………………………………………………………….. XVII ABBREVIATIONS……………………………………………………………. XIX NOMENCLATURE…………………………………………………………… XX CHAPTER 1 INTRODUCTION…………………………………. 1 1.1 Background to reconfigurable pin tooling ……………….………….. 1 1.2 Research motivation …………………………………………………. 2 1.3 Aims and objectives…………………………………………………… 4 1.4 Thesis contributions ………………………………………………….. 4 1.5 Thesis outline…………………………………………………………… 5 CHAPTER 2 LITERATURE REVIEW………………………… 9 2.1 Overview………………………………………………………………... 9 2.2 Pin design………………………………………………………………. 10 2.2.1 Pin cross-sectional shape…..………………………………….. 11 2.2.2 Pin tips……………………………………………………………. 11 IV 2.2.3 Pin density……………………………………………………….. 13 2.3 Adjustment methods…………………………………………………… 14 2.3.1 Support software……………..………………………………….. 14 2.3.2 Pin actuation methods………………………………………….. 16 2.3.3 Pin position determination….…………………………………... 21 2.3.4 Pin matrix clamping……………………………………………… 23 2.4 Tooling surface treatment and part shape control..………………... 27 2.4.1 Tooling surface treatment…………………………….………… 27 2.4.2 Part shape control……………………………………………….. 30 2.5 Pin tooling applications…………………………………..................... 33 2.5.1 Reconfigurable pin fixtures....……………………….…………. 33 2.5.2 Reconfigurable pin tooling for dies and moulds…………….... 46 2.6 Research gap…………………………………………………………... 57 CHAPTER 3 SYSTEM CONSTRUCTION AND 59 CALIBRATION …………………………………. 3.1 Introduction……………………………………………………………… 59 3.2 Screw pin tooling……………………………………………………… 60 3.2.1 Concept…………………………………………………………… 60 3.2.2 Pin actuation method……………………………………………. 61 3.3 HAVES test bed architecture ………………………………………… 61 3.3.1 HAVES test bed requirements…………………………………. 61 3.3.2 HAVES test bed architecture…………………………………… 63 3.4 Background to machine construction………………………………… 65 V 3.4.1 Introduction to the CNC machine……………………………... 65 3.4.2 Construction of CNC machine…………………………………. 66 3.5 HAVES system design………………………………………………… 68 3.5.1 System considerations……………………………..…………… 68 3.5.2 The original Gantry Machine introduction…………………….. 69 3.5.3 Initial conceptual design …..…………………………………… 72 3.6 Retrofit content…………………………………………………………. 74 3.6.1 Machine bridge…………………………………………………... 75 3.6.2 Screw-pin tooling………………………………………………… 75 3.6.3 Control system…………………………………………………… 77 3.6.4 Screw-pin adjustment tool……………………………………… 80 3.6.5 Machining tool modular…………………………………………. 82 3.6.6 Vacuum forming system development………………………... 83 3.7 Digitizing and inspection device……………………………………… 94 3.7.1 GOM ATOS II-400 digitizing system………………………….. 94 3.7.2 Digitizing process………………………………………………... 96 3.7.3 Digitizing component……………………………………………. 98 3.7.3 Evaluation of components……………………………………… 98 3.8 Completed HAVES TEST BED……………………………………… 99 3.9 Gantry machine system calibration…………………………………... 99 3.9.1 CNC machine test……………………………………………….. 99 3.9.2 Heater calibration………………………………………………... 103 3.10 Summary………………………………………………………….. …… 107 VI CHAPTER 4 METHODOLOGY FOR AUTOMATIC SHAPE 108 ADJUSTMENT OF SCREW-PIN TOOLING….. 4.1 Introduction …………………………………………………………….. 108 4.2 Procedures of digital tooling generation………………………..…… 109 4.3 Methodology for shape control……………………………………….. 110 4.3.1 Design model description………………………………………. 111 4.3.2 Screw pin tooling description…………………………………… 113 4.3.3 Adjustment description………………………………………….. 114 4.4 Support software framework………………………………………….. 117 4.5 Component geometry discretization…………………………………. 120 4.5.1 Three-dimensional CAD model discretization………………... 120 4.5.2 Three-dimensional physical component digitalisation………. 132 4.6 Screw-pin construction, adjustment and G code generation……… 136 4.6.1 Point processing…………………………………………... …… 137 4.6.2 Parametric screw-pin array pattern construction…………….. 141 4.6.3
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