Projects in Advanced Manufacturing and Production Systems (AMPS)

Design surface feature recognition for near net shaped manufactured components

Funding: ARC Discovery

The aim of this project is to investigate methods and techniques that, given an ab initio design requirement, allow databases of knowledge from previous designs to be intelligently searched for similar patterns, both geometric and physical state, that will assess the likelihood of a successful design and suggest potential alternatives based on previous experience The plan is to approach the research problem from a machine learning/pattern recognition point of view. By mapping the characterized properties into a search space of reduced dimensionality in which feature patterns have been pre-classified through supervised training, it should be possible to identify similar features.

Dimensional Control of Stamped Components for Optimized Assembly Operations

Funding: ARC Linkage, Ford Motor Company

Dimensional control is one of the most important challenges in automotive body assembly. The aim of this project is to develop a method of characterizing dimensional variation in a stamped sheet formed parts such that the effect of this variation on assemblies can be analysed. This will lead to an approach to flexible fixturing to minimizing assembly dimensional variation and improve dimensional quality.

Formability Of Fibre-metal Laminates

Funding: ARC Linkage, Ford Motor Company URP

The project addresses weight reduction and NVH improvement in automotive body structures. The work is focused on the development and application of metal (aluminium)- composite laminates, which have the potential to provide significant stiffness and strength at reduced weight for many components. The incorporation of polymer-based composite layers has the potential to improve NVH characteristics. Future work will focus on .nite element simulations of forming and development of damage models during forming.

Channel formed aluminium/Curv laminate

Video 1 of forming simulation Video 2 of forming simulation Video 3 of forming simulation

The main research findings to date are:

• maximum bond toughness achieved using anodised aluminium and a polypropylene hot-melt adhesive;
• spring-back in FML channel sections less than for steel when FML is formed with blank-holder force of 6kN and at a temperature close to 160oC - the melting point of the polypropylene-based composite.

Simpress Knowledge Capture And Integration System

Funding: ARC Linakge, Ford Motor Company, Simile Systems

A need was identified for a system to overcome problems arising in the stamping plant related to knowledge loss. This can occur from retirements, out-sourcing and right-sizing, and results in the repetition of mistakes and the reliance on a few key experience personnel to overcome design and production concerns. The same system could be used to capture experience and results from the STAMP (Stamping Technology for Automotive Manufacturing Processes) projects based within the stamping plant. This would allow the knowledge gained and work completed from the students to be transferred to Ford Motor Company of Australia. Simpress is used to capture Future Model Improvements and Lessons Learnt during the part lifecycle. This contributes to the development of an organisational experience base, which is then used as a reference when overcoming similar problems. Information is also fed back upstream into the design activities in order design out issues and break the cycle of repetition, which can result in a decrease in design and manufacturing lead times and a faster time to market. Simpress is a modular system based around a central database which can record text, images and data relating to the design and manufacture of stamped components. Modules can, and have been, added based on the outcomes of STAMP student research projects. This allows the work and results of these projects to be developed as tools that can be used by Ford Motor Company of Australia and other companies providing an applied beneficial outcome from the research projects.

Conceptual Metaphor And The Dynamics Of Human Activity Systems

Research into environmental and natural-resource issues is concerned with extending our understanding of how the world works and of how we can better manage our interaction with that world. As communities worldwide have become more aware of environmental degradation, and of the complexity and fragility of coupled natural-social systems, there has been an increasing focus on issues of the sustainability. In many cases ‘technology’ is seen as providing a way to achieve sustainable resource usage but, as has been widely demonstrated in practice, technological approaches that work in the short- term can fail dramatically in the long-term. Such problems are of central concern to the engineering community. Our chances of achieving sustainability depend directly on our level of understanding of the complex dynamics ( behaviour) of human activity systems. This project is designed to contribute to our understanding of the nature and dynamics of human activity systems and of the conceptual frameworks and methods that are needed to support the transition to the sustainable management of such systems. Because the interacting ‘parts’ of a human system are cognitive ‘agents’, the project is built on the assumption that an adequate approach to the sustainable management of human operations requires the blending of key concepts from dynamical systems theory and modern cognitive science.

Current research activities include:

• Theory and Explanation: Exploration of the notion that the creation of conceptual metaphor is the central process in the construction of theory and explanation. Application of this idea to support the development of (a) more useful theory in non-mathematical disciplines, and (b) better teaching in mathematics, system dynamics, and management;
• Integrative Research: The way that conceptual mapping provides the experiential basis of understanding. Identification of mathematical, dynamical and cognitive metaphors that are common to a range of disciplines and the use of these concepts to improve interdisciplinary communication and to support integrative research endeavours. The cross-disciplinary role of general system theory;
• Sustainability: The dynamics of human activity systems with a focus on stability and resilience. Application of bifurcation theory to issues of sustainability. The collapse of complex societies.

Development Of A Generic Model For Application Of Human System Constraints

Funding: Canon Australia

This project is an extension of research that developed an approach to the application of constraints in human-activity systems. The approach was tested and developed in two separate trials, for service teams in over-the-counter ( OTC) customer service. The next stage of this research is to test the model in a different business/ industry environment with different policy constraints, organisational pace and innovation requirements. Changes in the size, structure and type of the teams involved, will further test the theory. An industry partner for this testing phase has been secured in Canon Australia Pty Ltd. Canon has agreed to provide in-kind support for this initial project, which will involve application of the Game-Play Methodology to the Photo Video Repair Division and the Eco-Centre of the organisation.

Team-Based Knowledge Management

Knowledge Management is a burgeoning research and application field with knowledge being touted as one of the two most significant contributors to business competitive advantage of this decade. (The other is people – the ‘primary storage mechanisms’ for knowledge.) This project translates the Game- Play Methodology, a (localised) strategy for improving team performance, to the knowledge management domain. In business, at the team level, a game-play is a set of constraints applied to the members of a team with the intent of increasing system state knowledge (both current and immediate future) for all members, and thereby supporting achievement of the team goal In effect, GPM provides a framework for developing practical mechanisms for team-based knowledge management (game-plays).

Thermo-electro-chemo-mechanical properties of biological systems

Funding: ARC Discovery Project

The ability of a material to convert a mechanical strain into an electrical signal is not confined to certain minerals or engineered ceramics—many biological tissues are electromechanical transducers also. Though not widely recognized, this remarkable property is of interest to biologists because of its probable significance to biological systems. In addition, bio-electro-chemo-mechanical (BECM) transduction is of interest to ceramic scientists, electrical engineers, chemical engineers, solid state physicists and other researchers, who are concerned with the nature and utilization of thermo-electro-chemo-mechanical properties of smart biomaterials and structures. In this program we will develop rigorous adaptive theoretical and numerical models, informed by experiments, which will allow us to investigate the coupling thermo-electro-chemo-mechanical properties of smart biological systems. These models are essential for optimal design and management of smart biomedical components. Some specific but yet unsolved topics will be studied, such as the thermo-piezoelectric effect in biological materials, by the coupled global/local finite element method; biological tissue-based nanotube composites; neural–fuzzy logic techniques for analysing tissue growth and bone remodelling in fracture healing as well as optimisation techniques in designing layered bio-composites; micromechanics of bio-composite interfaces; detection and evaluation of microdamage in bone as a function of mechanical history; relationship between tissue microdamage and ultrastructure.

Simulation and design of flexible anchor fall arrest systems using LS-DYNA

Funding: CHLE Pty Ltd

When work is carried out at an elevated height with risk of falling, it is a requirement of Australian legislation to provide a safe working environment for those persons. Within the construction industry, falls from height account for the largest percentage of work related injuries and fatalities. The goal of this project is to focus on Height Safety Systems attached to roof tops as a means reducing injury in the event of a fall. These systems are referred to as Fall Arrest Systems. There have been a number of numerical studies conducted into characterising the performance of these systems when they are attached to building structure that is suitably rigid to withstand the forces exerted by a falling person, but in many cases the existing building structure is not suitable. For this reason, it has become necessary to design height safety systems such that they absorb maximum energy from the falling person for two reasons; to reduce to threat of injury to the worker; and to maintain the integrity of the building structure. To date, there has been no research conducted into flexible anchor systems due to the highly transient nature of the problem. It is for this reason that the explicit Finite Element Analysis program LS-DYNA is used. Due to its very powerful and flexible nature, insight is given in to the performance of flexible anchor fall arrest systems.

Production Decisions And Lot Sizing Incorporating Random Machine Failures

Funding: ANU FRGS, Ford Motor Company

This project investigates the performance of an unreliable production facility producing multiple parts using discrete event simulation. The discrete event model calculates costs associated with producing parts according to a given schedule. Using this model, optimisation techniques can be used to generate low-cost schedule parameters which take into account the expected frequency of machine failures.

Cost function and resume policy curves

International Technology Management In Multinational Corporations

Funding: Ford Motor Company

For multinational organizations such as Ford, the transfer and management of technology to its operations and subsidiaries around the world is key to its competitive success. The understanding of the technology transfer and diffusion process at the microscopic organizational level is not well understood.

This project aims to improve this process through the development of a model which can aid multinationals such as Ford (at a corporate level) to develop strategies for technology implementation. The model and accompanying methodology would be used in parallel to the vital technology adoption decision which typically faces corporate management. The model uses the following components to capture the technology transfer process: an investment appraisal framework which incorporates social cost-benefit analysis and the net present value (NPV) for both adoption and non-adoption; a riskless Social Discount Rate (SDR) based on the Social Rate of Time Preference (SRTP); a nations stock of Social Capital which is hypothesized to be inversely proportional to the SRTP; an Expected Value (EV) for both managers adoption/non-adoption and operators adoption/non-adoption, and; a game theoretic 2x2 management vs. operator matrix which combines EV estimates and allows transfer strategy refinement.

Integration Of Die Design And Tryout For Sheet Metal Stamping

Funding: Ford Motor Company URP

Die tryout is often described as a ‘black art’, where artisans (die designers and toolmakers) rely heavily upon past experience and trial and error experimentation to form acceptable stampings. Very little information exists in academic literature regarding the best methodology for solving sheet metal forming issues. As expected, the best references have originated from toolmakers handbooks and shop floor observations. Hence, this relatively unexplored aspect of stamping knowledge makes it an ideal research topic. The aim of this project is the development of a decision tree and associated framework that will allow die designers and toolmakers to make informed decisions when confronted by complex formability issues. As the framework is a knowledge driven system, benefits will be generally related to a greater understanding of forming processes and the possible corrective actions that can be applied in the case of formability issues.

Stamping Simulation

Development Of Plant Downtime Recording System

Funding: Ford Motor Company

Currently, classification structures for downtime recording in many automotive stamping factories are highly prescriptive. This means that in the event of a machine fault the operator is required to designate a predefined reason code to it. This can be a difficult task as, depending on the plant, there may be several hundred codes to choose from. Due to the highly subjective nature of the selection process, present regimes tend to suffer significantly from erroneous responses and poor operator participation. By limiting subjective input, this project aims to show that a less prescriptive questioning system can offer a better indication as to the system performance than current prescriptive systems. The work initially involved measuring the true losses being realized by the test plant.

Analysis of the Press System in the Stamping Process

Funding: ARC Linkage, Ford Motor Company

Many of the advances in sheet metal forming are being made in the automotive industry. The requirement for better processes automotive industry. The requirement for better processes and reduced cost is due to the cost/ quality competitiveness of the industry and the volume of parts produced. To reduce the amount of scrap and the time lost due to the defective part it is desirable to be able to identify a quality issue at the point that it occurs. This project investigates a force analysis system that identifies specific quality issues in formed panels with the aim of determining control relationships between the identified quality issues and process control variables.