Abstract
This paper describes an expert system for die design and process planning of sheet metal forming operations functioning on a part representation by custom-defined features input incrementally. Knowledge acquired from industrial experts pertains mainly to operations sequencing towards a complete process plan and to die and tool configuration, whilst knowledge acquired from handbooks pertains to calculations required to determine basic characteristics of individual manufacturing operations. The expert system is composed of seven modules: initial calculations, cutting-piercing, drawing-stamping, process planning, finishing, die and press selection, and tools selection. Part shape is converted from CAD environment to appropriate constructs in the expert system through a suitable interface to a library of customisable features. The expert system exports manufacturing advice in the form of a report. This can be used mainly by the product designer obtaining feedback on the production feasibility issue, or by the inexperienced die designer. In both cases design and manufacturing efficiency are greatly improved.
Similar content being viewed by others
References
Chen G., Chen J., Zhao Z., Ruan X. Y. (2005) An object-oriented hierarchical case representation of automotive panels in a computer-aided process planning system. The International Journal of Advanced Manufacturing Technology 26(11): 1323–1330
Chu C.-Y., Tor S. B., Britton G. A. (2008) Graph theoretic algorithm for automatic operation sequencing for progressive die design. International Journal of Production Research 46(11): 2965–2988
Ciurana J., Ferrer I., Gao J. X. (2006) Activity model and computer aided system for defining sheet metal process planning. Journal of materials processing technology 173(2): 213–222
CLIPS (2011) Online documentation version 6.24. http://clipsrules.sourceforge.net/OnlineDocs.html.
Du T., Liu Y., Zhang Z., Li Z. (2007) Fast FE analysis system for sheet metal stamping—FASTAMP. Journal of Materials Processing Technology 187–188: 402–406
ElMaraghy, H. (2007). Reconfigurable process plans for responsive manufacturing systems. In P. Cunha & P.Maropoulos (Eds.), Digital enterprise technology—Part 1. (pp. 35–44). Berlin: Springer.
Ghatrehnaby M., Arezoo B. (2012) Automatic strip layout design in progressive dies. Journal of Intelligent Manufacturing 23(3): 661–677
Giannakakis T., Vosniakos G.-C. (2008) Sheet metal cutting and piercing operations planning and tools configuration by an expert system. Journal of Materials Processing Technology 36(7–8): 658–670
Jia Z.-X., Li H.-L., Zhang X.-C., Wu H.-B., Fang M.-C. (2010) Study on the correlated design method of plate holes for progressive dies based on functional feature. International Journal of Advanced Manufacturing 49(1): 1–12
Karadgi, S., Muller, U., Metz, D., Schafer, W., & Grauer, M. (2009). Cost estimation of automotive sheet metal components using knowledge-based engineering and case-based reasoning. In International conference on industrial engineering and engineering management (IEEM 2009) (pp. 1518–1522). IEEE, Hong Kong.
Karayel D., Ozkan S. S. (2006) Distributed multi-agent system approach for sheet metal forming. Journal of Materials Processing Technology 177(1–3): 327–330
Kumar S., Singh R. (2011) An automated design system for progressive die. Expert Systems with Applications 38(4): 4482–4489
Lin B.-T., Chan C.-K., Wang J.-C. (2008) A knowledge-based parametric design system for drawing dies. The International Journal of Advanced Manufacturing Technology 36(7): 671–680
Lin B.-T., Hsu S.-H. (2008) Automated design system for drawing dies. Expert Systems with Applications 34(3): 1586–1598
Pan M., Rao Y. (2009) An integrated knowledge based system for sheet metal cutting-punching combination processing. Knowledge-Based System 22(5): 368–375
Ramana K. V., Rao P. V. M. (2004) Data and knowledge modeling for design–process planning integration of sheet metal components. Journal of Intelligent Manufacturing 15(5): 607–623
Shukora S. A., Axintea D. A. (2009) Manufacturability analysis system: Issues and future trends. International Journal of Production Research 47(5): 1369–1390
Singh R., Sekhon G. S. (2005) PROPLAN: An expert system for optimal planning of sheet metal operations. Journal of Materials Processing Technology 166(2): 307–312
Sunil V. B., Pande S. S. (2008) Automatic recognition of features from freeform surface CAD models. Computer-Aided Design 40(4): 502–517
Tang D., Gao B. (2007) Feature-based metal stamping part and process design. Part I: stampability evaluation. International Journal of Production Research 45(12): 2673–2695
Tor S. B., Britton W. Y., Zhang G. A. (2005) Development of an object-oriented blackboard model for stamping process planning in progressive die design. Journal of Intelligent Manufacturing 16(4–5): 499–513
Verlinden B., Duflou J. R., Collin P., Cattrysse D. (2008) Cost estimation for sheet metal parts using multiple regression and artificial neural networks: A case study. International Journal of Production Economics 111(2): 484–492
Vosniakos G.-C., Segredou I., Giannakakis T. (2005) Logic programming for process planning in the domain of sheet metal forming with progressive dies. Journal of Intelligent manufacturing 16(4–5): 479–497
Xie S. Q., Zhang W. J. (2008) Optimal sheet metal process planning: An agent-based approach. International Journal of Mechatronics and Manufacturing Systems 1(1): 131–153
Zhang W. Y., Tor S. B., Britton G. A. (2006) Indexing and retrieval in case-based process planning for multi-stage non-axisymmetric deep drawing. The International Journal of Advanced Manufacturing Technology 28(1): 12–22
Zhao Z., Shah J. J. (2005) Domain independent shell for DfM and its application to sheet metal forming and injection molding. Computer-Aided Design 37(9): 881–898
Zheng J., Wang Y., Li Z. (2007) KBE-based stamping process paths generated for automobile panels. The International Journal of Advanced Manufacturing Technology 31(7–8): 663–672
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Vosniakos, GC., Giannakakis, T. A knowledge-based manufacturing advisor for pressworked sheet metal parts. J Intell Manuf 24, 1253–1266 (2013). https://doi.org/10.1007/s10845-012-0664-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s10845-012-0664-3