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Aerospace Engineering 2007-03-01

Management promotes sharing The extensive use of CAD tools in aerospace design brings many benefits, but also a number of challenges. Getting robots to multi-task The demand to fulfill continually increasing customer requirements forces suppliers to offer state-of-the-art system manufacturing solutions.

Automotive Engineering International 2000-04-01

DaimlerChyrsler integrates product, process, and plant CATIA software is the core around which DaimlerChysler hopes to establish a virtual manufacturing system that allows new vehicles--and the plants that manufacture them--to be designed simultaneously with full simulation and visualization. The right bead in the right place at the right time Loctite assures customers of quality by assuming more responsibility for the adhesive-dispensing process. New manufacturing and design solutions Several software products will begin the new millenium with enhancements adding to a list of others that continue to provide good functionality and capability to engineers.

Aerospace Engineering: November 5, 2014

Adaptive trimming of composite parts Some of the techniques used in the Adaptive Manufacturing System are normal aerospace processes. The unique and enabling process is the scanning and adaptive trimming.

How Detroit Became the Automotive Capital

Published in 1996, as the 100th Anniversary of the automobile industry was celebrated in the United States, this book details the amazing story of how Detroit become the automobile capital of the U.S. All the of the automobile manufacturers in Detroit and surrounding areas are covered along with 49 additional topics that are woven in-between and presented in chronological order. This book includes over 500 time period photographs of factories, both inside and outside, personnel, cars, and logos. Readers will gain an appreciation for the talented people that created Detroit's automobile industry.

Advances in Side Airbag Systems

Thanks to years of research and development by vehicle manufacturers, suppliers, legislation, and the entire safety community, the side airbag has become a critical safety device to reduce injury and save lives. This new collection of technical research highlights the progression of these essential safety features, providing a complete and thorough perspective through the analysis of both early patents and recent side airbag system developments. Advances in Side Airbag Systems begins with an introduction by editor Donald E. Struble, chronicling the progress made since the mid-1980s in offering improved side impact protection to the motoring public. Authored by leading experts in their respective fields, this book features a comprehensive collection of 26 landmark technical papers. Its scope includes not only thorax airbags, but other inflatable devices designed for side impacts and rollovers.

Central Control of an Automated Riveting Machine and Robot Part Position with a Single CNC

There exists a demand in the aerospace industry for highly configurable and flexible automated riveting cells to manufacture small to medium sized panels of complex geometries. To meet this demand Electroimpact has developed a manufacturing system consisting of a stationary Electro-squeeze C-frame riveter, coupled with a robot part positioner to present the component to the process head tool point. The C-frame can install a wide range of aerospace rivets and perform specialist functions including backside countersinking operations, giving potential for double flush fastening. The geometric limitations and high implementation costs of large cartesian based positioning barges or fixed jig tooling and moving gantry riveters are avoided when exchanged for a robot part positioner.

Modeling Compressor Pressure Ratio vs. Mass Flow Rate Including Choke Line and Surge Line Using Scaling Theorem

In this paper, a procedure to obtain the compressor map (pressure ratio vs. mass flow rate) is showed by scaling of the available compressor maps with similar shape and design using scaling theorem. The reason to develop such procedure is that in industrial application, a new compressor map need be developed before the complete geometry and hardware of compressor are known. Such procedure is especially useful for users such as engine or vehicle OEM to quickly select turbocharger compressor independently. The scaling law is used to model the non-dimensional parameters of compressor head coefficient vs. mass flow coefficient. Detail procedure from the non-dimensional parameters to the final compressor performance data are described.
Technical Paper

Accepting CAD/CAM as a Way of Doing Business

This paper describes Computer-Aided Design and Manufacturing Systems in terms of software models usable in design and manufacturing engineering environments to increase overall productivity and product quality using fewer people in less time. Emphasis is placed on the key factors involved in promoting the acceptance of CAD/CAM from its initial introduction to managing the resulting organizational changes. Contemporary definitions of Computer-Aided Design and Computer-Aided Manufacturing are included along with a short history of computers used in engineering (including the use of personal computers). The field data includes sample CAD/CAM system utilization from our industry with estimated productivity figures and projected usage. It is presented in tabular and case form. The approach used is one of first identifying the capabilities and then referencing reported data from companies who have implemented the capability.
Technical Paper

Need for Robotics and Mechanical Research

Competition in manufactured goods from Japan has developed in recent years and now they are turning to automatic manufacturing systems and robots to maintain their lead. The United States needs to increase its development and utilization of robots in manufacturing and in other areas so that we can remain competitive. Some of our agricultural production is very well mechanized but other operations such as transplanting and fruit and vegetable harvesting are being done the same way as they were 50 or more years ago. Robots have wide potential application in agriculture to do the tedious tasks that are so common. Progress is being made in the development of a robotic sheep shearing machine and developments in robotic planting machines and citrus harvesters are being considered. Substitution of robots or other automatic machines for tedious tasks in agricultural operations will help keep food economical in price and improve working conditions for farm workers.
Technical Paper

Development of the Interative CAD/CAM System “NADAMS” in Nippondenso

NIPPONDENSO has originally developed a general purpose interactive CAD/CAM system called “NADAMS” which has been widely adopted all through its technical departments. “NADAMS” is the total CAD/CAM system for systematically supporting a series of processes extending from the design analysis stage with simulational prediction of function, performance and strength of products, through product design drafting stage, to the die design and manufacturing stage based on the geometric model stemmed in the product design analysis. This paper will discuss the concept of system design, the structure and function of the program, the modeling function and the data structure of NADAMS at NIPPONDENSO, focusing on; (1) the design and drawing system (2) the design analysis system (3) the respective product design and drawing system (4) the die design and manufacturing system (5) the solid modeling system
Technical Paper

MSG-3–A Method For Maintenance Program Planning

When a new aircraft is introduced into airline service, it must have a maintenance and inspection program approved by the Federal Aviation Administration (FAA). The “Airline/Manufacturer Maintenance Program Planning Document,” commonly known as MSG-3, is a method used (by the airlines and manufacturers) to develop the necessary maintenance/inspection program. The FAA participates with the manufacturer and airlines in the development of the program and finally, the FAA Maintenance Review Board (MRB) reviews the program, accepts it, and publishes it in an MRB report. This process is started early in the development of the new aircraft, well before the first flight, and concluded prior to delivery of the first aircraft.
Technical Paper

Implementation of CAD/CAM in a Consumer Electronics Company

CAD/CAM has been implemented at AT&T Consumer Products to improve the efficiency of data flow from design concept to manufacturing of the product. CAD/CAM has enhanced conceptual design and engineering processes, reconfigured product documentation, improved prototyping methods, and changed the interface to manufacturing. There are three interconnected turnkey CAD/CAM systems at AT&T CP-IN. The engineering system serves the engineer as a scratch pad for producing conceptual design and analysis, and is also used for “beta-site” testing of the complete CAD/CAM system for enhancements and for evaluating future technology. The second system resides in the Engineering Information Department and is used for design documentation and modeling. The manufacturing system is used to transpose design information for manufacturing, inspection, and quality control.
Technical Paper

Aspects Of Compound Production Of Diesel And Otto Engines For Passenger Vehicles

In the new engine factory of BMW Motoren Gesellschaft m.b.H. in Steyr, the manufacturing equipment was planned and realised for the production of both Diesel and Otto (i.e. Gasoline or Petrol) engines for passenger cars in form of a compound production system. Various aspects of compound production are presented with examples of the plant and the subsequent experience gained with it. A cost analysis comparison is presented between a production system using separate facilities and a compound production system. An essential requirement for the realisation of this concept was the harmonisation of the development aims for both Diesel and Otto engines. The resulting semi-flexible manufacturing system enables the production of both engine types on a continous basis. This system makes it possible to cater for changing customer demands whilst retaining the cost benefits.
Technical Paper

Air Transportation Capabilities in a Just-In-Time Environment

In my view, the “Just-In-Time” concept means improving product quality and managing all functions of a particular business in order to lower total costs. Since “Just-In-Time” is really the management process of making business work better, it is important to recognize some of the many issues outside of the manufacturing process itself that can affect the success of a “Just-In-Time” plan. These issues include vendor lead time control, delivery time management and distribution methods that optimize total unit costs. While there is no question that the largest component of high technology, high-value product Industries freight is shipped by surface carriers, the mode selection by manufacturers has been changing.

A Process for Utilizing Aerospace Propulsion Health Management Systems for Maintenance Credit

The process detailed within this document is generic and can be applied to commercial and military applications. It applies to the entire end-to-end health management system throughout its lifecycle, covering on-board and on-ground elements. The practical application of this standardized process is detailed in the form of a checklist. The on-board element described here are the source of the data acquisition used for off-board analysis. The on-board aspects relating to safety of flight, pilot notification, etc., are addressed by the other SAE Committees standards and documents. This document does not prescribe hardware or software assurance levels, nor does it answer the question “how much mitigation and evidence are enough”. The criticality level and mitigation method will be determined between the ‘Applicant’ and the regulator.

Vehicle Compatibility in Automotive Crashes

For years, reducing the number of traffic-related fatalities and injuries has been a major problem throughout the world. Today, it has gained much more momentum in view of rapidly increasing SUV, van, and light-truck populations relative to the number of passenger cars, and due to significant improvements in technologies that facilitate a better understanding of the interaction dynamics among widely differing size vehicles. Unless disparities in crashworthiness among vehicles of different masses, sizes, and structural characteristics in mixed crash environments are successfully taken into account, the challenge toward improved vehicle safety will continue. This two-part compendium provides the most comprehensive information available on the entire spectrum of vehicle crash compatibility. The first part presents oral comments captured from the 2003 SAE World Congress panel discussion on compatibility.
Technical Paper

Accounting for Manufacturing Variability in Interior Noise Computations

A formulation that accounts for manufacturing variability in the analysis of structural/acoustic systems is presented. The methodology incorporates the concept of fast probability integration with finite element (FEA) and boundary element analysis (BEA) for producing the probabilistic acoustic response of a structural/acoustic system. The advanced mean value method is used for integrating the system probability density function. FEA and BEA are combined for producing the acoustic response that constitutes the performance function. The probabilistic acoustic response is calculated in terms of a cumulative distribution function. The new methodology is used to illustrate the difference between the results from a probabilistic analysis that accounts for manufacturing uncertainty, and an equivalent deterministic simulation through applications. The probabilistic computations are validated by comparison to Monte Carlo simulations.
Technical Paper

Automated Drilling Systems of ARIANE 5 Structures

Two Automated Drilling Systems used in the manufacturing process of ARIANE 5 structures are described. One of them is a NC system where a specially designed machine runs around the two assembly tools of the Equipment Bay. The other one is a tailor made pneumatic system that also runs around the assembly tool of and Inter-Stage Structure. In both systems, conclusions about the use of those drilling units will be exposed. Finally, an automatic riveting unit will be introduced. This unit is nowadays in a development stage and will be integrated in both related systems.
Technical Paper

A Value Analysis Tool for Automotive Interior Door Trim Panel Materials and Process Selection

This paper describes a computerized value analysis tool (VAT) developed to aid automotive interior designers, engineers and planners to achieve the high levels of perceived quality of materials used in automotive door trim panels. The model requires a number of inputs related to types of materials, their manufacturing processes and customer perceived quality ratings, costs and importance of materials, features located in different areas of the door trim panel, etc. It allows the user to conduct iterative evaluation of total cost, total weighted customer perceived quality ratings, and estimates of perceived value (perceived quality divided by cost) for different door trim areas as well as the entire door trim panel. The VAT, thus, allows value and cost management related to materials and processing choices for automotive interiors.
Technical Paper

Development of Advanced Dimensional Control Method for Design for Six Sigma (DFSS)

The concept of design for six sigma (DFSS) offers a framework to design a product and process right the first time. In general, Taguchi's robust design method has been widely adapted in design optimization, which is a critical phase in any DFSS projects. The objective of the paper is to develop an advanced strategy in selecting an optimized product design and manufacturing process that should be insensitive to various multivariate variation patterns of the multi-stage manufacturing system. A Monte Carlo variation simulation based method is presented that integrates Mohalanobis Distance (MD) method, a discriminant analysis technique, to analyze the manufacturing variation patterns detected by using the multivariate statistical tool, such as principal component analysis (PCA). The proposed method will be explained with an example of an automotive assembly.