Variation Prediction and Source Identification for Zero-defect Machining Line

Purpose and goal

The goals was to develop tools and perform analysis for geometrical and dimensional variation prediction and source identification for zero defect manufacturing. Residual stresses, variations from upstream operations, fixture and tool induced errors are considered. A tool for the variation prediction and source identification has been developed. The tool supports process planners, fixture designers, and process controllers. A new analysis method combining the Contour Method with FEM and a new pallet based workholder for large components was developed and demonstrated.

Expected results and effects

The project results, i.e., the analysis methods, the methodology, the variation prediction and source identification tool and the new pallet based fixture for large components were demonstrated. These results are further published in journal and conference articles and contribute to the body of knowledge in the respective aspects of zero defect manufacturing. The industrial effect is very clear since the development works were formed from real industrial cases of the partner companies.

Planned approach and implementation

The project development work is anchored in three industrial cases each focusing in different scope and aspects of zero defect manufacturing. progress updates and workplans were discussed in biweekly pulse meetings and general assembly every half year. These helped to keep in-check in terms of time, resource allocation and research directions. Furthermore the meetings helped to share ideas among project partners. Public presentation, conference participations and demonstrations were made and can continue even beyond the project period.