Sajid Ullah BUTT

Conception Fabrication CommandeConception Fabrication Commande

Sajid Ullah BUTT

Conception et modélisation d'un montage de fabrication pour le balançage optimisé d'une famille de pièces

Arts et Métiers ParisTech - Centre de MetzLaboratoire de Conception Fabrication Commande EA 4495

Jury M. Cornel Mihai NICOLESCU, Professeur, KTH, Stockholm, Sweden Rapporteur

M. Jean-François RIGAL, Professeur, LAMCOS, INSA Lyon, France Rapporteur

M. Henri PARIS, Professeur, G.SCOP, Université Joseph Fourier, Grenoble, France Examinateur

M. Jean-François ANTOINE, Maitre de conférences, IUT de Nancy Brabois, France Co-directeur de thèse

M. Patrick MARTIN, Professeur, LCFC, Arts et Métiers ParisTech, Metz, France Directeur de thèse

Conception Fabrication CommandeConception Fabrication CommandePresentation layout

Sajid Ullah BUTT, PhD Defense 5 July 2012

• Context

• Positioning errors

• Compensation

• Objectives

• Workpiece repositioning through locators

• All the elements rigid

• Proposed fixturing system

• Analytical formulation

• Large displacements and Homogeneous Transformation Matrices

• Deformation of elastic elements and rigid body displacement of part on fixture under load

• Deformation of locators and contacts

• Lagrangian formulation

• Negligible friction, Small Displacements

• Convergence of non-linear contact deformation

• Work realized

• Conclusion

• Future work

Case Study

Context Kinematic Model Mechanical Model Conclusion and Perspectives

• Context

• Compensation

• Objectives

• Work realized

• Conclusion

• Future work

Case Study

CONTEXT KINEMATIC MODEL MECHANICAL MODEL CONCLUSION

Initial surface

Context

Optimal balancing• The final product should have a minimum

allowance for better machining• In case of perfect positioning, minimum rough part

radius should have to be r + h• ∆ is the positioning error between the final product

and the rough part’s central axis• The minimum radius of the rough part has to be R

for a good machining operation• More positioning error will increase the material

Allowance > Min chip thickness

Final part

Pallet

Spindle

Kinematics defects

Locators placement

Geometric/form defects

Deformation due to forces

Context

Workpiece/machine tool Positioning error • Variation among the parts of the same part family cause the positioning error during

fixturing• Positioning error of the workpiece affects the quality of the final product

Tool wearEffect of heatNC Code errors

Possible placement of

locators

Placement of locators• Block the 6-DOFs of the part

Placement procedure Choose the locating surfaces taking into account the

constraints of accessibility, load, external force and movements (Somashekar 2002)

Select the locators configurations (3-2-1, 3-2-1C, etc.) Choose the locators positions for the part stability (Roy

& Liao, 2002; Zirmi et al. 2009)

Positioning errors

3-2-1C

(H. Paris, 1995)

Geometrical and form defects• When workpiece is placed directly on the locators• Local geometrical defects cause the orientation error • The orientation error have more effect on the final product quality than the

translation error (Asante, 2009)

Positioning errorsCONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

Deformation of locators under external load• The locators and their contacts deform under clamping and machining

forces• Deformation depends upon the stiffness of the locators• Hertz contact theory may be applied to calculate the contact deformation• Locators deformations induce the workpiece displacement

Zero contact deformation

Including contact deformation

Positioning errorsCONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

Conception Fabrication CommandeConception Fabrication CommandePositioning errors

Machine tool/kinematic chain defects• Machine tool position uncertainty • Kinematic chain • Kinematic defects increase with the increase the

number of machine axes

Other Defects• Defects due to heat generation• NC code defects• Tool wear

How to Compensate these errors?

Conception Fabrication CommandeConception Fabrication CommandeError compensation

Existing methods• Changing the part program

• Easiest way (Ramesh et al. 2000)

• Orientation of the machine tool

Disadvantages• Need 4 or 5 axis machines• Very expensive for the existing production

Actual position

Ideal position

Compensated position

(Zhu et al. 2012)

PartPart

Pallet

Part programTool orientation

Baseplate

Pallet

6 DOF repositioning

Error compensationCONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

Our proposal• A 6-DOF workpiece repositioning

system is proposed

• A baseplate is introduced to avoid the positioning error caused by the geometrical defects

• Repositioning is performed through the positioning of the 6 locators

• Develop a fixturing system which can– Hold custom single and complex parts– Perform 6-DOF Repositioning of the part at desired position – Added to Single machine unit or production/assembly line – Minimum modifications on existing production line

Baseplate

Conveyor

Previous Workstation

Reconfigurable Pallet

Pallet

ObjectiveCONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

Single machine unit Production/Assembly line

Measure Calculate Compensate

Baseplate

Reconfigurable Pallet

Baseplate

MeasureWorkpiece geometrical errors• Offline: using CMM• Online: Integrated sensors

Calculate• The advancement of locators required to compensate the errors using

Homogeneous Transformation Matrices and Large displacements (Kinematic model)

• The errors due to deformation of elastic elements under load using Small Displacement hypothesis (Mechanical model)

CompensateThrough the axial advancement of 6 locators• Geometrical errors • Mechanical errors

ObjectiveCONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

Error compensation principle

• Context

• Compensation

• Objectives

• Work realized

• Conclusion

• Future work

Case Study

Objective• Repositioning of a part of a part family placed roughly with a precision of

some millimeters

Components– Part (Hip prosthesis)– Baseplate (Cuboid)– 6-Locators (Axial movement)– Pallet

All the elements are rigid

(Machine/Pallet reference)

Baseplate

Kinematic modelCONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

Baseplate

] = [P

bb’]

[Pb’F]=[PbP]

[POb’][POb]

Correction[PPF ]

Error to be corrected

Rigid link

Baseplate correction

through locators

Initial baseplate placement on the locators

Formulation

Y O(Machine/Pallet reference)

Baseplate

Baseplate Surface normals

CPT 12/14 Hip Prosthesis Zimmer

-10.00 10.00 30.00 50.00 70.00 90.00 110.00 130.000.00

Initial Position of the workpiece (2D Simulation)

Min Material (Chebyshev)

• Point P (intersection of two centerlines)• Definition of a plane• Simulation in 2D

-10.00 10.00 30.00 50.00 70.00 90.00 110.00 130.000.00

Min Material (Chebyshev)

• Point P (intersection of two centerlines)• Definition of a plane• Simulation in 2D

Initial Position of the workpiece (2D Simulation)

1’2’

Final calculated Position

Calculating point of contact in axis

Position calculation in 3D

Compensation of errorsCONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

2D Schematic explanation

Conception Fabrication CommandeConception Fabrication CommandeSimulation procedure: CAD ModelingCONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

Inverse impression of the workpiece for the simulation of

cutting tool path D=3mm

Cavity with original workpiece dimensions

Baseplate

Pallet

Workpiece

Boolean Operation

Conception Fabrication CommandeConception Fabrication CommandeCase study

Initial Data

Final required part position

Calculated positions of locators

Gray: Machined surfaceOrange: Rough surface

Simulated machining

Positioning error of workpiece after correction

Case study

Calculated positions of locators

Final Product

Calculated positions of locatorsPositioning error of workpiece after second side correction

Conception Fabrication CommandeConception Fabrication CommandeRobustness of model/Sensitivity Analysis

• Use of Plucker matrix• Precision of workpiece displacement as a function of locators’ positioning precision• Position uncertainty = Geometrical uncertainty + uncertainty due to temperature

Sensitivity analysis

Worst case

Precision of locator

• Context

• Compensation

• Objectives

• Work realized

• Conclusion

• Future work

Case Study

Conception Fabrication CommandeConception Fabrication CommandeMechanical model

• Clamping and machining forces and moments• Elements designed to be rigid

– Workpiece baseplate assembly– Mass elements

• Elastic elements– Locators (body and contact)– Baseplate at contacts– Clamps with imposed external displacements

• Small displacement hypothesis• Friction neglected• Effects of heat neglected• No slippage of clamps at contact

[K]3[K]4

[KE]1f

| T, F |

Conception Fabrication CommandeConception Fabrication CommandeFormulation

P b’F =

P b*F*

POb’

Pb*b’

Rigid link

Correction through locators

Error of the workpiece under load Machining forces and their displacement

P b’b*

Clamping forces and their

displacements

Initial baseplate locating under load

Correction

[K]3[K]4

[KE]1f

| T, F |

Work done by external force

Lagrangian Equation

Baseplate KE1

Machine/Pallet Reference

{ΔX,ΔY,ΔY}T: Linear displacement vector of point P{Δα,Δβ,Δγ}T: Angular displacement vector of point P{F}: Force vector{T}: Moment vector

U: Potential energy of the systemT: Kinetic energy of the systemW:Work done by the external forcesqi: Generalized coordinates

Potential Energy: U

Lagrangian Equation

Kinetic Energy: T t

Baseplate KE1

Machine/Pallet Reference

Locators

Clamps

(Lalanne et al. 1986)

Locator Pin

Locator model

• Screw-nut Wedge-slop locator • Rotation of knob causes axial

movement of locatorSlope 1:2

Screw M6x1

Locator diameter: 20mm

Length of locator: 68mm

Sphere radius: 20mm

Perforated plate Pitch = 40mm

2aL tLk k

Initial position of the surface

Final position of the surface

Locator axis

Deformed locator at the position having minimum potential energy

Formulation (Zero Friction)CONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

aL tLk k

Bending + Shear

Compression

Minimum energy (Menabrea’s theorem) Potential energy of locators

Locator’s Stiffness Matrix

Final position of contact surface after only locator deformation

Final position of contact surface after locator and contact deformation

X Zero contact deformation

Including contact deformation

Formulation

Deformation of contact (Hertz contact theory)CONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

Conception Fabrication CommandeConception Fabrication CommandeFormulation (Iterations procedure)

New stiffness matrices of each locator [K]i

Stiffness matrix [K] , overall displacement vector {∆X} and natural frequencies of the system using Lagrangian

Deformation of each locator{δ}i

Potential energy calculations

Deformation and stiffness of ith

locator body (δL, KL) i

Deformation and stiffness of ith contact (δC, KC) i

Overall stiffness of each locator and displacement vector of the workpiece ({∆Xnew} ) using inverse Plucker

[KNew]i = {F}i /{δNew}iT

{∆XNew}=[Plu]-1{δPlu}

Limite1001

XMAX New

iii KF

Final deformation/displacement vector and stiffness matrix of each locator and the

fixturing system

Yes/STOP

Kinetic energy and Work done

[K]i =[KNew]i

{∆X}= {∆XNew} +gain*({∆X} - {∆Xnew} )

{δNew}i= {δC}i +{δL}i

{∆XNew}

3D stiffness matrix of the locator body

[KL] i

[KC] i

3D stiffness matrix of the contact

3D equivalent stiffness matrix

[KNew] i

Force vector on the ith locator

[K]3[K]4

[KE]1f

Case study

| T, F |

Clamps

Baseplate (made of steel)

[K]3[K]4

[KE]1f

locators-baseplate contacting points

Contacting points of clamps

Case study (Input)

Locator stiffness| T, F |

Processed material• Prosthesis material : M30NW (X4CrNiMoN21)• ISO equivalent material: M3.2.C.AQ (Stainless steel Cast, Annealed quenched)

– Stainless steel 316LN (X2CrNiMoN18-13, Sandvik technical guide 2011)– σ = 880MPa

Cutting condition– Tool : CoroMill 216 ball nose endmill of 3 mm in diameter (2 teeth)– DOC, ap : 0.5 mm, Feed per tooth, Fz : 0.03 mm

– Cutting speed, Vc: 75 m/min, Spindle speed, N : 8000 RPM

Machining forces– Tangential force (Sandvik technical guide 2011)– Repulsive forces (Pruvot, 1993)

Case study (Input)CONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

Results without considering contact deformation

Case study (Results)

Results with considering contact deformation

Natural frequencies of the system Error compensation

Tool Excitation frequency=837 rad/sec

1 10 100 10001E-02

1 10 100 1000-70

Convergence of displacement vectorμ

No of iterations

1 10 100-60

Effect of gain on convergence μ

No of iterations

Convergence of parameter slowest parameter ∆γ

Conception Fabrication CommandeConception Fabrication CommandeRough contactsCONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

Baseplate-locator equivalent RMS roughness = 0.8 E-6 m

RMS Roughness (m)

Comparison between ideal and rough surface contacts

(Bahrami et al. 2005)

6.6% decrease

Conception Fabrication CommandeConception Fabrication Commande4-2-2 locator configuration

[K]3[K]4

| T, F |

| T, F |System stiffness

Comparison between 3-2-1 and 4-2-2

• Context

• Compensation

• Objectives

• Work realized

• Conclusion

• Future work

Case Study

Conception Fabrication CommandeConception Fabrication CommandeConclusion

• High quality baseplate is introduced• Compensation is performed through advancement of locators (kinematic model)• Deformation of each locator is calculated and its contact with baseplate under load (mechanical model)• Also its resultant rigid body displacement of the workpiece is calculated (positioning error)• Compensation is performed using kinematic model

Baseplate

Pallet

Kinematics defects

Locators placement

Geometric/form defectsDeformation due to forces

6 DOF part repositioning

6 DOF positioning using kinematic model– 3-2-1 locating configuration is used– All elements are considered rigid– Error compensation is performed through the axial translation of 6-locators

using HTM and LD– Validated on a case study of repositioning the hip prosthesis– Sensitivity analysis are carried out

Mechanical modeling of the fixturing system– The analytical model is developed– Deformation of locators under load is calculated – Workpiece-baseplate assembly is designed to be rigid– Locators, clamps and locator-baseplate contacts are assumed deformable– Small displacement hypothesis are used– Lagrangian formulation is used to calculate the mass & stiffness matrices and workpiece

displacement vector– Non-linear behavior of locator-baseplate contact is linearized– Demonstrated on a case study of 3-2-1 locating configuration and compared with 4-2-2

configuration of locators

• Analytical modeling gives very quick result as compared to numerical modeling

• The proposed mechanical model can easily be applied to more complex problems with multiple loads, different orientations and stiffness of locators and clamps

• The proposed fixturing system allows precise positioning of the workpiece at each workstation without the need of 4 or 5 axis machines or modifying the existing workstations

• Reduce dimensional errors, machining allowances and thus the material removal by uniformly centering the rough part to the required part• Consequently, it reduces the material waste

• Large parts could also be repositioned during assembling

ConclusionCONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

• The positioning error due to heat/temperature change can be introduced

• Construction of the fixturing system for validating the analytical model. We could not construct the model because of time and cost associated with precise part production

• The mechanical model calculates the deformation of locators as the result of an instantaneous force at a point. The model should be developed to simulate the whole tool path

Limitations and Future workCONTEXT KINEMATIC MODEL MECHANICAL

MODEL CONCLUSION

Conception Fabrication CommandeConception Fabrication CommandeScientific activities

Poster Presentation

• “Conception, Modélisation et Réalisation d'un montage modulaire rapide destine a la Fabrication Mécanique” J2A Arts et Métiers ParisTech, 8th-9th June 2010 (Poster Presentation)

National Colloquium

• S. U. Butt, J. F. Antoine, P. Martin, “Mechanical model for control of 6 DOF repositioning system”, 12th National Colloquium, AIP Primeca, Mont-Dore 29th March to 1st April 2011

Scientific Publications

• S. U. Butt, J. F. Antoine, P. Martin, “An analytical model for the repositioning of 6 DOF repositioning system”, Journal of Mechanics and Industry (Accepted June 2012 )

• S. U. Butt, J. F. Antoine, P. Martin, “An analytical stiffness model for spherical rough contacts”, Asian International Journal of Science and Technology in Production and Manufacturing Engineering (Submitted June 2012)

Thanks for your attention

Sajid Ullah BUTT

Documents

Siège - AQUA SERVICES - BATEAU · Siège Butt Seat Wise Pro-Verzion avec cadre moulé par injection et dispositifs pratiques de ... le fil de Dacron et les agrafes inoxydables sont

Muhammad Ul Rasool Ullah

Architectural Solutions for Next Generation Software Systemschristoph/seschool/... · Faheem Ullah & Nguyen Tran Architectural Solutions for Next Generation Software Systems CREST

Sajid Ullah BUTT

Selected Candidates for the post of Constable (BS-05 ...€¦ · 128 Muhammad bilal Fida hussain 37302-6458396-5 129 MUHAMMAD IKRAM MUHAMMAD NAWAZ SAJID 33201-9551276-7 130 Muhammad

A l'attention des cavalières et cavaliers, clubs …14).pdfColman Samy 3 3 Sajid Amine 2 2 Djaidi Majid 3 3 Taoui Driss 3 3 CSI1* Cavalier Nb chevaux autorisés Cavalier Nb chevaux

1/48 Sajid Ullah BUTT Conception et modélisation d'un montage de fabrication pour le balançage optimisé d'une famille de pièces Arts et Métiers ParisTech

FESCO :: Faisalabad Electric Supply Company Seniority/34.Khateeb(CatABC).pdf · 2020. 3. 18. · Hafiz Sajid Javid Hafiz Khalid Mehmood FESCO FINAL SENIORITY LIST OF IMAM MASJID OF

Effect of potassium and sulfur on grain yield, oil concentration … · 2019-03-07 · *Corresponding author’s email: saif2012aup@gmail.com Citation Saif Ullah, Shazma Anwar, Gul

Mandy blue threesome nasty redhead babe with awesome butt gets

NU Admission Homeadmission.nu.edu.bd/notice/PGD_120718.pdf · 2018-07-12 · jahirul islam md. mokter hossain md.habib ullah monirujjaman md. faridul islam soman bhuiyan ta.ul islam

UNE PUBLICATION DE LA DIRECTION DE SANTÉ ...csssdm.santelaurentides.qc.ca/fileadmin/documents/Acces...Gilles Chaput GRAPHISME Evelyn Butt Une publication de la DIRECTION RÉGIONALE

71 - ROBE RAGLAN POLYANNA POUR POUPEE D’ENVIRON 33 CM · Woll Butt – Qualité Haïti Aiguilles N° 2,5 & 3 pour poupée d’environ 25 cm (Ann-Estelle ou Patsy) Aiguilles N°

ORGANISATION EUROPEENNE POUR LA RECHERCHE NUCLEAIRE …€¦ · M. Waqar Ahmad Pakistan M. Ghulam Jilani Butt M. Zafer Alper Turquie M. Ufuk Gunes Également présents : Mme Halina

District:RAJANPUR · 2016-11-04 · District:RAJANPUR Roll No Candidate Name Total Roll No Candidate Name Total Roll No Candidate Name Total 89-101-121 Anayat Ullah 359 89-108-147

Description Author · ںیمیظنت یماوقلاا نیب rahat hussain anjum یسایس ےئاہ ماظن یلباقت m hameed ullah ماظن یسایس لاپین روااکنلیرس

List of candidates who have applied for list 12th b… · 11 1101460 ESA TAWSEEF AHMAD SHEIKH 12 1101487 ESA BENU ALI 13 1101488 ESA SHUGUFTA QADIR 14 1101501 ESA SAJID MUSHTAQ WANI

Beautiful sheman fabiana loves a big dick in her appetizing butt pics

Lempdesville-lempdes.fr/wp-content/uploads/2014/09/Lempdes-info... · 2019-03-11 · février 2016 • Yanis Robert OLLIER le 6 février 2016 • Sajid MARGOUM le 7 février ... Consultation

Publications - Shaikh Khalifa Bin Zayed Al-Nahyan Medical ...€¦ · Rukhsana Sher, Naﬁsa Fatima, Arshad Kamal Butt, Shabbir Ahmed Bhatti, Naseem Akhtar and Shaﬁa Waheed. 2011