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1. INTRODUCTION
Manufacturing is an indispensable part of the economy and is the central activity that encompasses product, process, resources and plant. Nowadays products are more and more complex, processes are highly-sophisticated and use micro-technology and Mechatronic, the market demand (lot sizes) evolves rapidly so that we need a flexible and agile production. Moreover manufacturing enterprises may be widely distributed geographically and linked conceptually in terms of dependencies and material, information and knowledge flows.
In this complex and evolutive environment, industrialists must know about their processes before trying them in order to get it right the first time. To achieve this goal, the use of a virtual manufacturing environment will provide a computer-based environment to simulate individual manufacturing processes and the total manufacturing enterprise. Virtual Manufacturing systems enable early optimization of cost, quality and time drivers, achieve integrated product, process and resource design and finally achieve early consideration of producibility and affordability.
Virtual manufacturing (VM) is a kind of knowledge and computer-based system technology that integrates manufacturing activities dealing with models and simulations instead of objects and their operations in the real world. This provides a digital tool for the optimisation of the production efficiency through simulations prior to the start of actual production. The concept, significance and related key techniques of VM have been addressed by Lawerence Associate [3], while the contribution and achievements of VM have been reviewed by Shukla et al. [4].
A typical VM system consists of a manufacturing resource model, a manufacturing environment model, a product model and a virtual prototyping model [5]. There is a lot of active research in both conceptual and constructive VM systems. Onosato and Iwata [1] developed the concept of a VM system and Kimura [7] described the product and process model of a VM system. Based on the concept and the model, Iwata et al. [2] proposed a general modelling and simulation architecture for a VM system. Recently, Gausemeier et al. developed a Cyberbike VM system for real time simulation of an enterprise that produces bicycles. Using the VM system, various Page 1
As, since 10 years, several projects and workshops have dealt with the Virtual Manufacturing thematic, we will first define the objectives and the scope of VM and the domains that are concerned. The expected technological benefits of VM will also been presented. We will also present the socio-economic aspects of VM. This study will take into account the market penetration of several tools with respect to their maturity, the difference in term of effort and level of detail between industrial tools and academic research. Finally the expected economic benefits of VM will be presented.
The concept, classification and benefits of VM are presented and discussed in detail. The associated technologies, their key techniques and current research work related to materials processing are highlighted. In addition, the social and technological obstacles in the development of a VM system and some practical application examples of VM on materials processing are also discussed.
We will also describe the trends and exploitable results in machine tool industry (research and development towards the 'Virtual Machine Tool'), automotive (Digital Product Creation Process to design the product and the manufacturing process) and aerospace.
The term Virtual Manufacturing is now widespread in literature but several definitions are attached to these words. First we have to define the objects that are studied. Virtual manufacturing concepts originate from machining operations and evolve in this manufacturing area. However one can now find a lot of applications in different fields such as casting, forging, sheet metalworking and robotics (mechanisms). The general idea one can find behind most Page 2
Fig 1. Virtual Manufacturing [5] Environment: supports the construction, provides tools, models, equipment, methodologies and organizational principles, Exercising: constructing and executing specific manufacturing simulations using the environment which can be composed of real and simulated objects, activities and processes, Enhance: increase the value, accuracy, validity, Page 3
The scope of VM can be to define the product, processes and resources within cost, weight, investment, timing and quality constraints in the context of the plant in a collaborative environment. Three paradigms are proposed in [5]: a) Design-centered VM: provides manufacturing information to the designer during the design phase. In this case VM is the use of manufacturing-based simulations to optimize the design of product and processes for a specific manufacturing goal (DFA, quality, flexibility,) or the use of simulations of processes to evaluate many production scenarios at many levels of fidelity and scope to inform design and production decisions. b) Production-centered VM: uses the simulation capability to modelize manufacturing processes with the purpose of allowing inexpensive, fast evaluation of many processing alternatives. From this point of view VM is the production based converse of Integrated Product Process Development (IPPD) which optimizes manufacturing processes and adds analytical production simulation to other integration and analysis technologies to allow high confidence validation of new processes and paradigms. c) Control-centered VM: is the addition of simulations to control models and actual processes allowing for seamless simulation for optimization during the actual production cycle.
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2.2. Applications of VM
The attractive applications of VM include: analysis of the manufacturability of a part and a product; evaluating and validating the feasibility of the production and process plans; optimisation of the production process and the performance of the manufacturing system. Since a VM model is established based on real manufacturing facilities and processes, it does not only provide realistic information about the product and its manufacturing processes, but also allows for the evaluation and the validation of them. Many iterations can be carried out to arrive at an optimal solution. The modelling and simulation technologies in VM enhance the production flexibility and reduce the ``Fixed costs'' since no physical conversion of materials to products is involved. Apart from these, VM can be used to reliably predict the business risks and this will support the management in decision making and strategic management of an enterprise. Some typical applications of VM are as follows:
1. VM can be used in the evaluation of the feasibility of a product design, validation of a production plan, and optimisation of the product design and processes. These reduce the cost in product life cycle. 2. VM can be used to test and validate the accuracy of the product and process designs. For example, the outlook of a product design, dynamic characteristics analysis, checking for the tool path during machining process, NC program validation, checking for the collision problems in Page 6
3. Classification of a VM system
3.1. Classification based on type of system integration
According to the definitions proposed by Onosato and Iwata, every manufacturing system can be decomposed into two different sub-systems: a real and physical system (RPS); and a real informational system (RIS). An RPS is composed of substantial entities such as materials, parts and machines, that exist in the real world. An RIS involves the activities of information processing and decision making. A computer system that simulates the responses of the RPS is called a ``virtual-physical system' (VPS), whereas that simulates a RIS and generates control commands for the RPS is called a ``virtual-informational system' (VIS).
According to the product design and process design functions, VM can be sub-divided into product design centred VM, production-centred VM and control-centred VM. Product designcentred VM makes use of different virtual designs to produce the production prototype. The related information of a new product (e.g. product features tooling,etc.) is provided to the designer and the manufacturing system designers for supporting the decision making in the product design process. Production-centred VM simulates the activities in process development and alternative process plans. It aims at the rapid evaluation of a production plan, the operational status of a Page 7
VM is used in the interactive simulation of various manufacturing processes such as virtual prototyping, virtual machining, virtual inspection, virtual assembly and virtual operational system, etc. 1. Virtual prototyping (VP) mainly deals with the processes, tooling and equipment in casting, blanking, extrusion, injection moulding, etc. VP makes use of modelling and simulation techniques to analyse the factors affecting the process, product quality and hence the material properties, processing time and manufacturing costs. The virtue of VP lies not only in the reduction of the fabrication of physical prototypes, shortening the product development time and cost, but also in supporting product design and presentation through qualitative simulation and analysis [5]. These facilitate the discussion, manipulation and modification of the product data model directly among personnel with different technical backgrounds. 2. Virtual machining mainly deals with cutting processes such as turning, milling, drilling and grinding, etc. The VM technology is used to study the factors affecting the quality, machining time and costs based on modelling and simulation of the material removal process as well as the relative motion between the tool and the workpiece. It can be used to evaluate the feasibility of a part design and the selection of processing equipment, etc. 3. Virtual inspection makes use of the VM technology to model and simulate the inspection process, and the physical and mechanical properties of the inspection equipment. This aims at studying the inspection methodologies, collision check, inspection plan, factors affecting the accuracy of the inspection process, etc. 4. In assembly work , VM is mainly used to investigate the assembly processes, the mechanical and physical characteristics of the equipment and tooling, the interrelationship among different parts and the factors affecting the quality based on modelling and simulation. It can also be used to predict the quality of an assembly, product cycle and costs as well as to Page 8
The development of VM demands multi-disciplinary knowledge and technologies related to the hardware and software of the computer, information technology, microelectronics,
manufacturing and mathematical computation. Some of these technologies are comparatively mature. However, most of them have to be further developed to form an integrated VM platform. 4.2. Establishment of virtual physical units
The establishment of a virtual physical unit (e.g. a material processing unit, machining unit, inspection unit, assembly unit, robot, and material delivery devices, etc.), which mimics the operation of a real physical unit, forms the crucial basis for the development of a VM system. The performance of a VM system could be seriously affected by the accuracy, precision and reliability of the information outputs from an individual virtual physical unit. The establishment of the virtual physical units includes the integration and management of 3D solid models, and models for the simulation of motion and the mechanical properties of the virtual physical units. 3D geometrical solid models and simulation are comparatively mature. There is a number of CAD/CAM software and object-orientated programming languages, and image processing software that are available for performing the tasks.
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Product design validation is vital to the verification of the functional, reliability, and durability requirements of a given design, whereas process validation is critical to verify what production processes can best meet the cost and quality goals of a given design. The evaluation of a kind of VM system can be divided into two main streams, which are the evaluation of the performance of the system and the validation of the related information generated by the VM system for a particular product development. The former determines the functional capability of the VM system. This includes the validation Page 10
AVM system is required to handle a large amount of work on complex mathematical computation, graphical image processing, data exchange and remote communications. These include the construction of 3D solid models, 3D animation, virtual reality (VR), graphical image processing manufacturing resources planning, product features processing, acquisition of manufacturing know-how and processing, etc. Even with the rapid advancement of the computational power of the computer system and information technology, it is still far from being sufficient to meet the further demanding technology for VM. On the other hand, the external interface and the speed of I/O of the computer have to be enhanced to meet future needs.
The rapid development of digital network communication and computer sciences provides indispensable tools for the development of VM applications. However, VM is developed based on human know-how and understanding of the manufacturing processes. The successful development of VM depends much on present knowledge and capabilities of applying modern mathematical tools to describe and to present the knowledge in a systematic manner. Although some research work has been devoted in researching the core theories of the manufacturing processes, a large number of problems has not yet been solved and is still dependent on human judgement by experience. For example, present understanding on the selection of optimal cutting conditions for metal removal processes, factors affecting the successful draw of a sheet metal product, etc., is still far from perfect.
Apart from technological know-how on the manufacturing process and modelling, a VM system is needed to absorb and acquire a large amount of information for it to operate. This demands a better learning and knowledge acquisition capability of the RM facilities so as to Page 12
A complete VM system is a large system. It does not only perform the task of data exchange with various software systems (e.g. CAD/CAM/CAE, databases for resources and knowledge, etc.), but also needs to exchange information among different hardware facilities of different manufacturers. In order to ensure efficient operation of a VM system, there is a need for establishing an unified data standard or data conversion software for facilitating the data exchanging among the VM, CAD/CAM/CAE and RM systems. Although many related standards have been built by the ISO organisation, the data standards used in production facilities and software of different manufacturers might be different. Since the development and the launch of standards are usually lag far behind the real production needs, different countries and manufacturers have developed less compatible standards for their own use. This introduces problems for the development of VM to be used over the Internet.
A VM system is not only required to integrate different dispersed and independent databases for information and knowledge bases within an enterprise but also the databases from the suppliers, customers and other enterprises. There is a need to establish a complete database for supporting the VM operation. Nowadays, the theoretical bases and technologies for database management have achieved a substantial success. However, the knowledge bases for the manufacturing technologies are expanding enormously. Only a very small portion of these resources has been converted to computer databases. The successful conversion of the know-how of the manufacturing technologies to computer databases demands the investment of a huge amount of manpower, money and capital. In addition, further work is still required to upgrade the database Page 13
The contribution and significance of the VM system are on its capabilities of providing compatible and equivalent results to a RM system so as to allow for the improvement of the product design and manufacturing processes. Under various environments, especially for new product development without the presence of standard evaluation techniques, the development of VM applications presents problems on verifying the compatibility and accuracy of a VM system with a RM system as well as the measure of the effectiveness of a VM system in improving the product quality and manufacturing process. This demands for the development of related evaluation methods and tools.
In addition to the technical obstacles presented during the development and application of VM technologies, there exist some social problems that include the following. 1. The development of a VM system and its applications is a large establishment. From a longterm point of view, VM offers an attractive solution for an enterprise to improve its efficiency and productivity. However, VM might not be a turnkey solution to improve the current status of an enterprise from a short-term point of view. The development of a VM system also demands the investment of a large amount of capital and management effort. Active support from research organisations, enterprises and government are vital to the successful development of a VM system. 2. The development of VM applications includes many enterprises, business sectors and technological eras. However, different standards are adopted by different enterprises and a large difference is usually found among sectors. Even within the same business sectors, difference still exists. The way to develop a unified standard and regulations is a social problem which needs further work. 3. Although, the concepts of open resource sharing and risk sharing are highlighted in VM, it is inevitable for an enterprise to consider keeping their information confidential. Since the scope of Page 14
As small modifications in manufacturing can have important effects in terms of cost and quality, Virtual Manufacturing will provide manufacturers with the confidence of knowing that they can Page 15
It is important to understand the difference between academic research and industrial tools in term of economic aspects. The shape of the face in the diagram presented in Fig. 3 in [9] is defined by two curves: effort against level of detail where level of detail refers to the accuracy of the model of simulation (the number of elements in the mesh of a FEM model or the fact if only static forces are taken into account for a simulation, effort against development in time is a type of time axis and refers to future progress and technological developments (e.g. more powerful computers or improved VR equipment). Universities develop new technologies focusing on technology itself. Researchers do not care how long the simulation will need to calculate the results and they not only develop the simulation but they need to develop the tools and methods to evaluate whether the simulation is working fine and whether the results are exact. On the other hand, industrial users focus on reliability of the technology, maturity economic aspects (referring to the effort axis) and on the integration of these techniques within existing information technology systems of the companies (e.g. existing CAD-CAM systems,). To our mind, Virtual Manufacturing is, for a part of its scope, still an academic topic. But in the future, it will become easier to use these technologies and it will move in the area of industrial application and then investments will pay off. For example in the automotive and aerospace companies in the late 60s, CAD was struggling for acceptance. Now 3-D geometry is the basis of the design process. It took 35 years for CADPage 17
7.1 Machine-tool
The trend in the machine tool manufacturers sector concerning Virtual Manufacturing is research and development towards the Virtual Machine Tool.
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The goal of the Virtual Machine Tool is to reduce time and cost for the developing of new machine tools by introducing virtual prototypes that are characterized by a comprehensive digital geometrical design, and by the simulation of (1) the stationary behaviour of the machine structure, (2) the dynamic behaviour of moving parts, (3) the changing of signals and state variables in electronic circuits and (4) by the simulation of the manufacturing process itself. Nowadays, the simulation activities are isolated from each other. Current research is combining different types of simulation to reflect various interdependencies, like e.g. elaborating the frequency response with FEA and combining this with a bloc simulation of the machine. The process simulation of forming processes is almost state-of the-art in industry, whereas the simulation of cutting processes is an item for international research (this excludes the pure NCprogram simulation, which is widely used in industry, but which does not reflect the realistic behaviour of the interaction of machine tool, tool and work piece during cutting operations).
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7.3 Aerospace
Virtual Manufacturing in aerospace industry is used in FEA to design and optimise parts, e.g. reduce the weight of frames by integral construction, in 3D-kinematics simulation to program automatic riveting machines and some works dealing with augmented reality to support complex assembly and service tasks (the worker sees needed information within his glasses). The simulation of human tasks with Manikins allows the definition of useful virtual environment for assembly, maintenance and training activities [8].
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As a conclusion of this paper, we can say that we have now reached a point where everyone can use VM. It appears that VM will stimulate the need to design both for manufacturability and manufacturing efficiency. Nowadays, even if there is a lot of work to do, all the pieces are in place for Virtual Manufacturing to become a standard tool for the design to manufacturing process: computer technology is widely used and accepted, the concept of virtual prototyping is widely accepted, companies need faster solutions for cost / time saving, for more accurate simulations, leading companies are already demonstrating the successful use of virtual manufacturing techniques. Nevertheless, we have to note that there are still some drawbacks to overcome for a complete integration of VM techniques: data integrity, training, system integration. Moreover if large manufacturing enterprises have developed and applied with success VM technologies (aerospace, automotive, VM is a capital intensive technology and a lot of SMEs do not have the wherewithal to integrate them). Certainly there is more work to do. We must continually work to improve the ease of use, performance and verisimilitude of the simulations. The graphical user interface and the seamless connection to CAD systems will require continuous improvements. The Internet will be a powerful driver for new ways of working and interacting with diverse teams. And, most of all, we must work to create systems that are easy to use for the purposes intended rather than continually adding the latest features. There is much to be done, but the tools are in place and the path is visible, if not clear. I believe that Virtual Manufacturing is today a competitive advantage for many companies around the world and soon will be a business requirement for all manufacturing companies.
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