PROCEEDINGS OF THE

THIRTIETH INTERNATIONAL MATADOR

CONFERENCE

PROCEEDINGS OF THE

THIRTIETH INTERNATIONAL MATADOR

CONFERENCE

held in Manchester 31st March - 1st April 1993

Edited by

A. K. KOCHHAR Lucas Professor of Manufacturing Systems Engineering

Manufacturing Division Department of Mechanical Engineering

UMIST

DEPARTMENT OF MECHANICAL ENGINEERING UNIVERSITY OF MANCHESTER INSTITUTE OF SCIENCE AND TECHNOLOGY

in association with

MACMILLAN EDUCATION

!50th YEAR

M MACMILLAN

© Department of Mechanical Engineering University of Manchester Institute of Science and Technology

1993 Softcover reprint of the hardcover 1st edition

1993 978-0-333-59648-7

All rights reserved. No reproduction, copy or transmission of this publication may be made without written permission.

No paragraph of this publication may be reproduced, copied or transmitted save with written permission or in accordance with the provisions of the Copyright, Designs and Patents Act1988, or under the terms of any licence permitting limited copying issued by the Copyright Licensing Agency, 90 Tottenham Court Road, London W1P 9HE.

Any person who does any unauthorised act in relation to this publication may be liable to criminal prosecution and civil claims for damages.

First published 1993 by the Department of Mechanical Engineering

UMIST P.O. Box 88, Manchester M60 1 QD

in association with THE MACMILLAN PRESS LTD

Houndmills, Basingstoke, Hampshire RG21 2XS and London

Companies and representatives throughout the world

ISBN 978-1-349-13257-7 ISBN 978-1-349-13255-3 (eBook) DO 10.1007/978-1-349-13255-3

A catalogue record for this book is available from the British Library

I

THIRTIETH INTERNATIONAL MATADOR

CONFERENCE 31st March - 1st April 1993

ORGANIZING AND REVIEWING COMMITTEE

Professor A. K. Kochhar (Chairman) Dr. J. Atkinson Dr. G. Barrow Dr. P. Brunn

Dr. M. Burdekin Dr. N. R. Chitkara

Dr. W. Graham Dr. R. G. Hannam

Dr. S. Hinduja Mr. R. Kirk

CONFERENCE SECRETARIES

Mrs. S. Mellor Ms. F. Sharrock

CONTENTS

KEYNOTE ADDRESS: Competitiveness in Manufacturing -Putting all the elements together J. PARNABY, CBE

MANUFACTURING SYSTEMS Applying the lessons learned from 146 manufacture to the next generation of regional aircraft

N. MASOM 5

Total manufacturing systems: The operational reality B. TROUGHT 15

A systematic basis to manufacturing G.G. ROGERS 21

Strategic planning of information systems H. CATHER and S. KARABABAS 27

Organisational aspects of information systems design L.E. DAVIS, J.P. DUBERLEY, S.A. BLENKINSOP and N.D. BURNS 35

Effective tool maintenance information management C. O'BRIEN, H. SCHAFER and J.K. BRYANT 43

Repetitive manufacturing management information systems A. DeTONI and R. PANIZZOLO 49

An effective computer based assembly line balancing method X. MA and H.W. LIU 57

TQM2: A meta-methodology for revitalizing flagging quality initiatives S. SMITH, D. TRANFIELD, S. WHITTLE and M. FOSTER 65

Continous quality improvement in short run manufacture L.R. CARTER and C. BUTLER 75

Total productive maintenance: Quality and responsibility through worker involvement A.A. SWINTON and A.J. DAY 83

Set up and maintenance issues arising from the implementation of cellular manufacture in an injection moulding factory

J.S. MORTON, P.J. ROSAIR, M.J. HOLGATE and P.G. MAROPOULOS 95

A study of feedscrew container handling systems on liquid packaging lines with a view to optimisation C. LEE and H.G. PATEL 103

vii

METAL CUTTING AND GRINDING The machining of TiA 1-based intermetallics

H. ZANG, M.L.H. WISE and D.K. ASPINWALL Ill

Some ultrasonic effects in machining materials encountered in the offshore industries D. CLIFTON, Y. IMAI andJ.A. McGEOUGH 119

Conventional machining of an aluminium based SiC reinforced metal matrix composite (MMC) alloy R.T. COELHO, S. YAMADA, T. le ROUX, D.K. ASPINWALL and M.L.H. WISE 125

Surface roughness model for end milling metal matrix composite (A1/SiC) M. ALA UDDIN, M.A. EL BARADIE and M.S.J. HASHMI 135

CAE applied to twist drills R. LEADBETTER and M. MCCOLL 143

Strategy of machinability of alluminium alloys for free cutting J. KOPAC, M. SOKOVIC,A. SMOLEJ,A. GORCENKO and V. DRAGOJEVIC 151

On line tool life prediction for tool replacement strategy in FMS workstation S. NOTO LA DIEGA, A. PASSANNANTI and Z. TANG 157

Recognition of chip forms by means of dynamic force spectrum analysis W. GRZESIK 163

A review of polycrystalline cubic boron nitride cutting tool developments and application A.M. ABRAO, D.K. ASPINWALL and M.L.H. WISE 169

The failure of metal cutting tools at tool/work disengagement Z.Q. QIAN, J.F.L. CHAN and P.M. BRAIDEN 181

The real contact length in grinding based on depth of cut and contact deflections W.B. ROWE, QI HONGSHENG, M.N. MORGAN and ZHENG HUANWEN 187

The identification of dressing strategies for optimal grinding wheel performance W.B. ROWE, XUN CHEN and M.N. MORGAN 195

METAL FORMING Development of roll-less forming process for ultra-thin wall welded pipe production

T. NAKAKO, A. TAKEZOE and S. INOUE 205

An automatic speed programme generation for SRM G. PELLEGRINI, C. GIARDINI and A. BUGINI 211

Modelling of deep-drawing of complex shaped components using slip-line methods F. BOOR 217

Cold extrusion of flanges on cylindrical hollows B. LENGYEL, S.A. SHAHMORADI and I.A. CHAUDHRY 227

Computer aided metal flow simulation and die design optimization for axisymmetric forging process F. DIKO and M.S.J. HASHMI 235

Electric discharge machining of an aluminium alloy silicon carbide reinforced metal matrix composite T. le ROUX, M.L.H. WISE and D.K. ASPINWALL 247

Vlll

The investigations of electrochemical machining process when using non profiled electrode A. RUSZAJ, M. ZYBURA-SKRABALAK and M. CHUCHRO

Experimental study of the printing of solder paste using the metal blade squeegee system I. ISMAIL, S.H. MANNAN, N.N. EKERE and E.K. LO

Variable composition laser cladding of copper alloys M. ELLIS, D.C. XAIO, W.M. STEEN and C. LEE

MANUFACTURING EDUCATION A hypermedia-based tutoring system for education in mechanical engineering

K. CHENG and W.B. ROWE

Benefits of joint roles to manufacturing education C.J. BACKHOUSE and N.D. BURNS

The application of advanced manufacturing technology in New Zealand R.H.A. SEIDEL, J.D. TEDFORD, M.H. NORTON and I.M.P. SLY

A proposal for a postgraduate CAD/CAM course I.I. ESAT

EXPERT SYSTEMS Increasing the acceptance of knowledge-based systems

R.P. MAIN and K. OLDHAM

Lot production: A rule-based expert system approach A. DE TONI, G. NASSIMBENI and S. TONCHIA

Industrial applications of model-based approaches to fault diagnosis N.F. DOHERTY and A.K. KOCHHAR

Practical development of knowledge-based systems in manufacturing K. OLDHAM, R.M. HATHER, J. HALTON and A.K. KOCHHAR

Fuzzy selection of concurrent engineering implementation tatics F. LETTICE, A. MATIN and S. EVANS

NEURAL NETWORKS Control of multisensor systems by neural networks

Z. NAGY and T. SZALAY

Neural network techniques for metal forming design A. BARCELLONA

Development of an intelligent robotic cell C. LEE and M-H. YU

A transputer based neural network development system for industrial control applications J.P. RUIZ-MIGUELA and P.J. BRUNN

Intelligent scheduling of sequence dependent set-up times using neural network T.J. SUH and I.I. ESAT

ix

255

263

267

277

285

291

295

303

315

323

331

345

355

361

367

375

381

MATERIALS MANAGEMENT System dynamic models for improving the design and operations of supply chains

D.R. TOWILL and M.M. NAIM

Performance and organisation of very small firms in the supply chain A. DE TONI, M. MUFFATTO, G. NASSIMBENI and A. VINELLI

Integrated materials management-redefining the value chain P. HINES

Use of statistical techniques in the dynamic modelling of an industrial supply chain M. GRIFFITHS, K. HAFEEZ and M.M. NAIM

MANUFACTURING SYSTEMS MODELLING Performance modelling in CIM

S.I. MARRIOTT, V.C. MACHADO, V.R. NEWMAN and P.J. SACKETT

An evaluation of Siman for simulating FMS tool management systems N.T. WANG and R.G. HANNAM

The design of cellular manufacturing systems and whole business simulation P.A. LEWIS and D.M. LOVE

On the modelling and simulation of flexible assembly systems using coloured petri-net P.P. CICCIOLA, R. GROPPETTI and M. LA CAVA

Towards a standard in FORCAST A.N. GODWIN AND D. SAUNDERS

DESIGN Performance Improvement of slowly moving fluid power drives using pulse-width-modulation

S.M.HARB

Establishing a rule base for the computer aided design of tooling for the multi-stage pressing of cylindrical cups

B. FOGG

Finite element analysis of press tools K.W. DUNLOP and U.P. SINGH

A photo-elastic and strain gauge technique of stress analysis in rod-drawing M.T. HILLERY and V.J. McCABE

Computer aided analysis of high frequency induction heating process of steel J. DOPKIN, K. SADEGHIPOUR and K. LI

Capabilities of a new and generalized approach for creating solid models from two-dimensional drawings

K.S. TAM and J. ATKINSON

CAD modelling of sculptured workpieces from physical models WEIYIN MA, J.P. KRUTH and P. VANHERCK

Representation and manipulation of fastener knowledge G. ZHONG and M. DOONER

X

389

397

405

413

423

429

435

443

451

461

469

477

485

493

501

511

519

COMPUTER AIDED PROCESS PLANNING CCSPLAN: A generative process planning system

ZHENGXU ZHAO and R.W. BAINES 527

A knowledge-based representation and a decision-based approach for advanced manufacturing systems A. CHEP and B. ANSELMETTI 535

Disassembly process planning M. SIMON and T. DOWIE 543

Information mapping between a feature-based design system and an integrated process planning system

J.X. GAO and K. CASE 551

Computer integrated design and manufacture of complex geometries in concurrent engineering B. GOPALAKRISHNAN and V. PANDIARAJAN 559

Integration of constraint and solid modellers A.J. MEDLAND, G. MULLINEUX and A.H. RENTOUL 565

Representation of surfaces in 3D wireframe models ZHENGXU ZHAO, G.N. BLOUNT, R.M. JONES and R.W. BAINES 573

Symbolic representation of geometrical data of extrusion dies S.G. AHMED, J.M. SHARP and A.M. DORE 581

Representing geometrical and technological data in feature-based part models S.R.K. JASTHI, A.V.S.R.K. PRASAD, V. ARORA, P.N. RAO, U.R.K. RAO and N.K. TEWARI 589

Modelling and optimisation of turning operations R.M.D. MESQUITA and E.P. HENRIQUES 599

ROBOTS Prototype of perceptive glove with feedback force for telerobotics in flexible manufacturing manipulation

A. ROVETTA, X. WEN, A. TOGNO, S. MILANESI and E. GENTILI

A system for on-line performance monitoring of industrial robots A.G. STARR, I.J. KENNEDY and R.J. WYNNE

Flexible vision-assisted handling system for the packaging of food products T. BONFIELD, A.M. DORE and J.M. SHARP

Microprocessor controlled pneuma-hydraulic positioning system for a robotic manipulator S.M. DE ALMEIDA and T. ROACHE

A structured approach to vision monitoring I.M.P. SLY

XI

611

617

627

637

645

MANUFACTURING METROLOGY Assessing fundamental geometric form from measured coordinate data

M.G. COX and P.M. HARRIS

Position calibration software for the form assessment of complex workpieces A.B. FORBES

Measurement of the accuracy of a Puma 560 industrial robot D.A. HORNSHAWandA.J. DAY

Criteria for possibilities of industrial robot application to measurement and inspection operations L.NAWARA

Evaluation of polished silicon wafers' micro-roughness by atomic force microscope Y. SAMITSU

Contour assessment of CNC machine tools M. GULL and N. GARNER

Automatic position and orientation correction for automated assembly robots H.J. REA, R. RAESIDE and J. LEWIS

Digital filtering in roughness measurements A.A. BRUZZONE and P.M. LONARDO

SCHEDULING Scheduling for success in process industries

B.W. DINES

A real-time scheduling method using hierarchical decentralized decision makers for flexible manufacturing systems

K. MORI, M. TSUKIYAMA and T. FUKUDA

Real-time routing selection in flexible manufacturing systems M.P. FANTI, E. LO VALVO, M. PIACENTINI and G. PISCITELLI

Flow-shop scheduling: Effect of various priority rules on minimizing multiple criteria MUJANAH, EZAT AGHA and M. EL BARADIE

xii

655

663

671

681

685

691

699

705

713

719

727

733

Foreword

by Conference Chairman

It gives me great pleasure to introduce to you the proceedings of the 30th International MATADOR Conference. The Conference has attracted papers from thirteen countries other than the United Kingdom and hence fully justifies the word 'International.'

The MATADOR Conference was established in 1959, which makes it one of the longest established Conferences in the field of manufacturing in the world. It covers a wide area of interest to researchers and industrialists working in a range of manufacturing industries. The topics covered by the successive Conferences have always reflected the important developments in research in the whole of manufacturing. It is therefore natural that while maintaining a strong technological base, this Conference has attracted papers in a number of related areas. For example, this year we have a large number of papers on expert systems and neural networks. This reflects the increasing growth of research and development in the areas of expert systems and neural networks applied to manufacturing. Another new theme at this conference is manufacturing education which is of considerable interest to academics and industrialists alike.

As for the future, intelligent automation is providing for the simultaneous achievement of considerable flexibility, precision and productivity. Manufacturing, as a whole, is moving from art to science. Machines, and the associated control systems increasingly incorporate very considerable intelligence. This trend will accelerate over the years to come. It will become increasingly necessary to bring together, in a creative manner, the human intelligence and the machine intelligence, for solving the complex manufacturing problems. Research work in these areas will be very challenging since it will be necessary to devise new paradigms and structures which recognise the increasing amount of intelligence built into machines. This will prove a very considerable challenge for the researchers as well as practitioners in industry.

I hope that the readers will find the papers interesting and stimulating.

PROFESSOR A.K. KOCHHAR

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