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KNOWLEDGE BASED SYSTEM FOR DESIGN/SELECTION OF BENDING DIE COMPONENTSPresented edit Master subtitle style Click to by Sujit M. Mulay (P11CC013) Guided by Dr. S. Kumar
KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF
2/16/13
Objectives of Proposed Research Work The overall goal of proposed research work is to develop
an knowledge based system for design/selection of bending die components, Following objectives are identified to fulfill the said goal.1. 2. 3. 4. 5.2 2
Literature Review. Identification of major die components. To Prepare Production Rules based on Knowledge acquired from various experts. To develop modules for major components of bending die. Selection of suitable programming language.
KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION KNOWLEDGE BASED 2/16/13 6. Execution of the SY3STEM system. OF BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Outline Introduction To Bending Die. Bending Die Components. Need of Expert System In Die Design. Expert System Methodology. Development Procedure of Expert System for die design. Literature Review. Tentative Research Plan for Next Semester. References.
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION KNOWLEDGE BASED SY3STEM 2/16/13 OF BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
What is bending ??? Bending is defined as straining of metal around straight
axis. Bending is done using press brakes. Capacity of press brake varies from 20 to 200tons.
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION KNOWLEDGE BASED SY3STEM 2/16/13 OF BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Importance of bending process In todays practical and cost-conscious world, sheet-metal
parts have already replaced many expensive cast, forged, and machined products.
Bending is one of oldest forming process. It is a flexible process. It is a mass production process. Variety of different shapes can be produced. It is through metal bending that the process of creating a
roof for a building or manufacturing vehicles became easy.
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF KNOWLEDGE BASED SY3STEM 2/16/13 BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Bending die A bending die is a specialized tool used in manufacturing
industries to shape material using the press.
Types of bending die
1. V - bending die 2. U - bending die 3.Wiping bending die
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V bending die
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U bending die
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF KNOWLEDGE BASED SY3STEM 2/16/13 BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Wiping bending die
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF KNOWLEDGE BASED SY3STEM 2/16/13 BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Exploded View of Bending Die -
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF BENDING KNOWLEDGE BASED SY3STEM 2/16/13 DIE COMPONENTS FOR DESIGN/SELECTION OF
Bending die componentsDie block A die block is a construction
component that houses the opening and receives punches. Material Tool SteelPunch plate Similar to die block used to hold and
support the punch. Material Hardened Tool Steel11 11 KNOWLEDGE BASED SY3STEM hold the material down KNOWLEDGE BASED Used FOR Stripper plate SY3STEMto DESIGN/SELECTION OF 2/16/13 BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
on
the die block and strip the material off the
Punch Tool attach to the upper portion of die set that
gives actual shape to the part. Material - hardened steel or tungsten carbide. Guide post It function together with guide bushings to
align both the upper and lower die shoes precisely.
Material Pin - Hardened Tool Steel, Bushing Highly
wear resistance aluminium-bronze. Shank Shank is sometimes provided in upper shoe by
which the whole tool is clamped to the ram of the press.
Material Chemical Silicon Steel (S50C), Grey Cast Iron (FC250), Stainless Steel (SS400).12 12 KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION KNOWLEDGE BASED SY3STEM 2/16/13 OF BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Bolster plate - Bolster plate, sometimes called press
table is positioned on top of the press bed.
It is a heavy plate, ribbed with T slots precision aligned to the frame with dowel pins. Material - steel Cushion pin - Metal pins used in conjunction with a die
cushion to transfer pressure from the cushion to the bottom of a die pad, It can also be used to lift the part out of the die. Material Cold roll steel13 13 KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION KNOWLEDGE BASED SY3STEM 2/16/13 OF BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Need of Expert System in Die Design In conventional process of die design, the success of the die
design and manufacturing is largely depends upon the skill and the experience of the die designer. Poor Documentation of die designing rules. Commercially available CAD/CAM software's are less
efficient. They provide some assistance in drafting and analysis in die design process, but human expertise is still need to arrive at the final design. time and cost of product.
To reduce the time spent on product development, delivery
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF KNOWLEDGE BASED SY3STEM 2/16/13 BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Expert System Definition Expert system = knowledge + problem-solving methods Expert systems (ES) is a branch of applied artificial
intelligence involving that expertise, which is the vast body of task-specific knowledge, is transferred from a human to a computer. This knowledge is then stored in the computer and users call upon the computer for specific advice as needed (Liao, 2005) An expert system is a system that employs human
knowledge captured in a computer to solve problems that ordinarily require human expertise (Turban,1995)
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History of Expert System DENDRAL - In1965 at Stanford University developed by
J. Lederberg in conjunction with E.A. Feigenbaum and B.G. Buchanan. MYCIN - Developed by E.H. Shortlie at Stanford
University at the end of the 1970s. Expert system is the first realisation in the field of AI
techniques.
In the 1980s, expert systems proliferated as they were
recognized as a practical tool for solving real-world problems. Universities offered expert system courses and two thirds of the Fortune 1000 companies applied the technology in daily business activities.
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION KNOWLEDGE BASED SY3STEM 2/16/13 OF BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Features of Expert System Problem solving in the area of expertise. Availability: On any suitable computer hardware. System is exible enough as its knowledge base can be updated and
modied, if necessary. Cost: The per-user cost is greatly lowered. Permanence: will last indefinitely (depending on the hardware). Reliability: provide a second opinion to human experts, mediate
opinions. Explanation: the expert system may always explain how it reached the
conclusion. Response: may provide fast or real-time response for critical
applications.17 17 KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION KNOWLEDGE BASED SY3STEM 2/16/13 OF BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Architecture of Expert System
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF KNOWLEDGE BASED SY3STEM 2/16/13 BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Expert system Methodology Determination of goal & preliminary investigation Problem analysis, System draft, System prototype & validation of the prototype In house testing using a real life case study Complete testing of real life data of user System validation and documentation Fixing of error and continuous enhancements19 19 KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF BENDING KNOWLEDGE BASED SY3STEM 2/16/13 DIE COMPONENTS FOR DESIGN/SELECTION OF
Problem Identification and feasibility analysis
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Problem must be suitable for an expert system to solve it.
- Cost-effectiveness of the system has to be established (feasibility). System Design and ES Technology Identification -
- System is being designed. The needed degree of integration with other subsystems and databases is established. - Concepts that best represent the domain knowledge are worked out. - Inferencing should be established with sample cases to represent the knowledge and to perform.20 20 KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION KNOWLEDGE BASED SY3STEM 2/16/13 OF BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Development of Prototype knowledge engineer works with the expert to place the
initial kernel of knowledge in the knowledge base. specific tool chosen for the project
knowledge needs to be expressed in the language of the
Testing and Refinement of Prototype -
- Using sample cases, the prototype is tested, and deficiencies in performance are noted. End users test the prototypes of the ES.
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF KNOWLEDGE BASED SY3STEM 2/16/13 BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Complete and Field the ES -
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Interaction of the ES with all elements of its environment, including users and other information systems, is ensured and tested. ES is documented and user training is conducted
Maintain the System -
- System is keep current primarily by updating its knowledge base. - Interfaces with other information systems have to be maintained as well, as those systems evolve.KNOWLEDGE BASED SY3STEM 2/16/13 22 KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION BENDING DIE COMPONENTS 22 OF FOR DESIGN/SELECTION OF
Development Procedure of Expert System for bending die design
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION KNOWLEDGE BASED SY3STEM 2/16/13 OF BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF BENDING KNOWLEDGE BASED SY3STEM 2/16/13 DIE COMPONENTS FOR DESIGN/SELECTION OF
Knowledge Acquisition - The domain knowledge for
design of bending die is collected through on line and off line consultation with design experts, tool design engineers of different industries, referring research articles, catalogue and manual of different design and manufacturing industries. Knowledge Representation -
Production rule based - The most common method of knowledge representation is ruled based systems. The knowledge collected is represented using rules. The syntax of a production rule is IF < condition >, THEN < action >25 25 KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF KNOWLEDGE BASED SY3STEM 2/16/13 BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Verification& Sequencing of production rules Production
rules framed for each module crosschecked from die design expert by presenting them IF condition of the production rule of IF THEN variety. The framed rules are presented in structured manner. hardware elements depending upon memory requirement, processing speed and needed configuration should be selected. The proposed systems are implemented on PC (Pentium 4 CPU, 2.4 GHz, 2GB of RAM) with Autodesk AutoCAD 2008.
Selection of operating system and hardware - Suitable
Selection of development language Languages used so
far in AI systems are FORTRAN, KEE, OPS, PROLOG, TURBOPROLOG and LISP.
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF BENDING DIE KNOWLEDGE BASED SY3STEM 2/16/13 COMPONENTS FOR DESIGN/SELECTION OF
Construction of Expert System shell - Developers of expert
systems realized very early that by separating the knowledge base containing the problem specific information from the rest of the system. Most of that system could be easily adapted to a new
problem by replenishing the knowledge base with information about the new problem.
This separation led to the development of expert system
KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION KNOWLEDGE BASED SY3STEM 2/16/13 27 BENDING DIE COMPONENTS 27 OF FOR DESIGN/SELECTION OF
shells, offering much of the functionality of an expert system through the user interface, dialog component, inference engine, and explanation generator while leaving the population of the knowledge base to the application programmer.
Choice of search strategy - The production rules and the
knowledge base of the system are linked together by an inference mechanism, which makes use of forward chaining.
forward chaining Data driven process. Backward chaining - Goal driven process.
Preparation of user interface - The purpose of user interface
in the development of each module is twofold1. 2.
To enables the user to input the essential sheet metal component data. To displays the optimal decision choices for the users benefit.
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KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF KNOWLEDGE BASED SY3STEM 2/16/13 BENDING DIE COMPONENTS FOR DESIGN/SELECTION OF
Literature ReviewSr. Researcher No1 Uzsoy, et. al., (1991)
System DetailsRule based KBC implemented using turbo prolog.
RemarksA simple sheet part with total of eight features; four holes with two holes radius of 2 units, two hoes of radius 1 unit and four bends. System does not provide process planning and manufacturability of bending Data base for present m/c required to be made
2 Ching, Z. et.al. (1994) 3 Ching, Z. et. al. (1996) 4 Ong, S. et al. (1997) 5 Gupta, et al., (1998)
Autolisp integrated into AutoCAD Sheet metal bending machine selection model
Fuzzy set theory for sheet metal Does not provide optimal bending sequences bend sequencing only provides feasible solution Automated process planning for Separate illustrations are given for each of the robotic sheet metal bending modules for different operations; press brake Presently sheet with 23 bends can be addressed for its process planning & other sequences.
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KNOWLEDGE BASED SY3STEM 2/16/13 KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF FOR DESIGN/SELECTION OF BENDING DIE COMPONENTS
Sr. No Researcher6 Inamdar, M. et al. (2000) Ching, Z. (2001) Shigeru, A. et al. (2002)
System DetailsArtificial Neural Network for measuring Sprinback in v-Bending Torque equilibrium and optimal strip working sequence for bending progressive die Sheet metal Bending Sequence and robot grasping positions are determined by Graphical method and geometrical bending features
RemarksMore the Data for initial training the more accurate will the result Two stage model generated for customized problem Only in 55% cases model provides accurate result and around 27 % moderate result.
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Ruffini, R. (2002)
Neural network for springback minimizationInitial data is required for training of ANN model so, not suitable for initial use where precise o/p is required CAPP process planning of Bending and Piercing System required commercial CAD/CAM software
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Kim, C. et al. (2002)
KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION KNOWLEDGE BASED SY3STEM 2/16/13 30 FOR DESIGN/SELECTION OF 30 OF BENDING DIE COMPONENTS
Sr. No11
ResearcherRico, J.C. et al. (2003) Rico, J.C. et al. (2003) Ehrismann, R et al.(2004) Pathak, K. et al. (2005) Sousa, L.C. et al.(2006)
System Details
Remarks
Automatic bending Sequence for Model is based on Part-tool collision and Parallel bends tolerance constraint with lower process time optimisation Automatic bending Sequence for Model is based on Part-tool collision and Parallel bends tolerance constraint with lower process time optimisation Expert system for Bending Sequence System is not able provide optimized solution
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Neural Network for finding sheet To reduce the error % of results in b/w metal bending process FEM and NNT high no. of cases are parameters required for training Numerical simulation coupled Time required for numerical simulation is with Genetic Algorithms used to High around 36 h. optimized V & U bending processes
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Ching, Z. et Selection of bending Good for customized problem al.(1998) tools only and bending sequence
KNOWLEDGE BASED SY3STEM 2/16/13 31 KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION BENDING DIE COMPONENTS 31 OFFOR DESIGN/SELECTION OF
Sr. No17
ResearcherBozdemir, M. et al. (2008) Kazan, R. et al. (2009) Kontolatis, N. et al. (2010)
System DetailsANN for Springback in V-Bending ANN for springback in wipe bending Optimization of Bending Process planning parameters
RemarksGood results are obtained for customized problems Optimized results are not obtained System is not capable to provide solution for sprinback in present approach Experimental data is used for learning model
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Baseri, H. et al. (2011)
Spring Back Modelling by fuzzy learning model in V Bending
KNOWLEDGE BASED SY3STEM 2/16/13 32 KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION FOR DESIGN/SELECTION OF 32OF BENDING DIE COMPONENTS
TENTATIVE RESEARCH PLAN FOR NEXT SEMESTERMonths ActivityDec. 2012
Jan. Feb. 2013 2013
Marc April May June h 2013 2013 2013 2013
Regular visits to Industries Develop ment of modulesKNOWLEDGE 2/16/13 33 KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION Execution BASED SY3STEM BENDING DIE 33 OFFORsystem COMPONENTS of DESIGN/SELECTION OF
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ThankYou.
KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF
2/16/13