A data-driven optimization model to collaborative manufacturing system considering geometric and physical performances for hypoid gear product

Abstract A data-driven optimization model to collaborative manufacturing system considering geometric and physical performances is proposed to improve competitiveness of hypoid gear product development facing with economic globalization. Firstly, to deal with the vagueness or impreciseness of the voice of customer (VOC), the fuzzy quality function deployment (fuzzy-QFD) using fuzzy weighted average method in the fuzzy expected value operator is introduced into hypoid gear manufacturing. It can convert them into the critical to qualities (CTQs), and the technical geometric and physical performance requirements. And then, the multi-objective optimization (MOO) modification of machine settings is proposed to establish a basic data-driven model for collaborative system. Different with the conventional modification only considering geometric performance, it provides an improved modification also considering the physical performances. Finally, a double-curved shell model of hypoid gear finite element is used to perform the numerical loaded tooth contact analysis (NLTCA), as well as to establish the data-driven relationships between machine settings and physical performance evaluations. Immediately, whole development is divided into three sub-problems: i) optimal operations of the noise factors by measurement and numerical control (NC) compensation, ii) identification of the prescribed ease-off topography by multi-objective optimization using iterative reference point approach and iii) modification considering geometric performance by a trust region algorithm with step strategy. The numerical instance in practical applications is given to verify the proposed methodology.

[1]  Ahmet Kahraman,et al.  A load distribution model for hypoid gears using ease-off topography and shell theory , 2009 .

[2]  Chelsea C. White,et al.  Key factors in the successful application of quality function deployment (QFD) , 2001, IEEE Trans. Engineering Management.

[3]  Zheng Wang,et al.  Real-time error compensation of a three-axis machine tool using a laser tracker , 2013 .

[4]  Weiming Shen,et al.  An agent-based service-oriented integration architecture for collaborative intelligent manufacturing , 2007 .

[5]  Ashraf Labib,et al.  A Fuzzy Quality Function Deployment (FQFD) model for deriving optimum targets , 2001 .

[6]  Han Ding,et al.  An accurate model of high-performance manufacturing spiral bevel and hypoid gears based on machine setting modification , 2016 .

[7]  Min Xie,et al.  Dealing with subjectivity in early product design phase: A systematic approach to exploit Quality Function Deployment potentials , 2008, Comput. Ind. Eng..

[8]  N. Rogacheva.  The Theory of Piezoelectric Shells and Plates , 1994 .

[9]  Han Ding,et al.  Data-driven operation and compensation approaches to tooth flank form error measurement for spiral bevel and hypoid gears , 2018, Measurement.

[10]  Ahmet Kahraman,et al.  An Ease-Off Based Optimization of the Loaded Transmission Error of Hypoid Gears , 2010 .

[11]  Massimo Guiggiani,et al.  Multi-objective ease-off optimization of hypoid gears for their efficiency, noise, and durability performances , 2011 .

[12]  Qi Fan,et al.  Higher-Order Tooth Flank Form Error Correction for Face-Milled Spiral Bevel and Hypoid Gears , 2008 .

[13]  Han Ding,et al.  Nonlinearity analysis based algorithm for indentifying machine settings in the tooth flank topography correction for hypoid gears , 2017 .

[14]  Jubo Li,et al.  A network-based manufacturing model for spiral bevel gears , 2018, J. Intell. Manuf..

[15]  Kaj Madsen,et al.  Methods for Non-Linear Least Squares Problems , 1999 .

[16]  Erasmo Carrera,et al.  Refined hierarchical kinematics quasi-3D Ritz models for free vibration analysis of doubly curved FGM shells and sandwich shells with FGM core , 2014 .

[17]  Jiafu Tang,et al.  Rating technical attributes in fuzzy QFD by integrating fuzzy weighted average method and fuzzy expected value operator , 2006, Eur. J. Oper. Res..

[18]  Richard Y. K. Fung,et al.  Fuzzy regression-based mathematical programming model for quality function deployment , 2004 .

[19]  Jinxing Xie,et al.  An intelligent hybrid system for customer requirements analysis and product attribute targets determination , 1998 .

[20]  Yoji Akao,et al.  Quality Function Deployment : Integrating Customer Requirements into Product Design , 1990 .

[21]  Nathan R. Soderborg,et al.  Design for Six Sigma at Ford , 2004 .

[22]  Graham Wilson,et al.  Six Sigma and the Product Development Cycle , 2005 .

[23]  Uwe Gaiser,et al.  The Ultimate Motion Graph , 2000 .

[24]  Han Ding,et al.  A multi-objective correction of machine settings considering loaded tooth contact performance in spiral bevel gears by nonlinear interval number optimization , 2017 .

[25]  A. Love.  A treatise on the mathematical theory of elasticity , 1892 .

[26]  V. Simon.  Optimal Tooth Modifications in Face-Hobbed Spiral Bevel Gears to Reduce the Influence of Misalignments on Elastohydrodynamic Lubrication , 2014 .

[27]  Han Ding,et al.  A novel operation approach to determine initial contact point for tooth contact analysis with errors of spiral bevel and hypoid gears , 2017 .

[28]  Ignacio Gonzalez-Perez,et al.  Numerical approach for determination of rough-cutting machine-tool settings for fixed-setting face-milled spiral bevel gears , 2017 .

[29]  Sheng Li,et al.  Prediction of mechanical gear mesh efficiency of hypoid gear pairs , 2010 .

[30]  Nicholas Fantuzzi,et al.  Effect of agglomeration on the natural frequencies of functionally graded carbon nanotube-reinforced laminated composite doubly-curved shells , 2016 .

[31]  Yian-Kui Liu,et al.  Expected value of fuzzy variable and fuzzy expected value models , 2002, IEEE Trans. Fuzzy Syst..

[32]  André Crosnier,et al.  Collaborative manufacturing with physical human–robot interaction , 2016 .

[33]  Bingheng Lu,et al.  A web-based manufacturing service system for rapid product development , 2004, Comput. Ind..

[34]  Kai Xu,et al.  A web services-based approach to develop a networked information integration service platform for gear enterprise , 2012, J. Intell. Manuf..

[35]  Massimo Guiggiani,et al.  Optimization of the Loaded Contact Pattern in Hypoid Gears by Automatic Topography Modification , 2009 .

[36]  F. Litvin,et al.  Gear geometry and applied theory , 1994 .

[37]  Massimo Guiggiani,et al.  Robust Optimization of the Loaded Contact Pattern in Hypoid Gears With Uncertain Misalignments , 2010 .

[38]  Hamid M. Lankarani,et al.  Compliant contact force models in multibody dynamics : evolution of the Hertz contact theory , 2012 .

[39]  Chiang Kao,et al.  Fractional programming approach to fuzzy weighted average , 2001, Fuzzy Sets Syst..

[40]  Massimo Guiggiani,et al.  Nonlinear identification of machine settings for flank form modifications in hypoid gears , 2008 .

[41]  J. Hauser,et al.  The House of Quality , 1988 .

[42]  Di He,et al.  A new analytical identification approach to the tooth contact points considering misalignments for spiral bevel or hypoid gears , 2018 .

[43]  Massimo Guiggiani,et al.  On the Identification of Machine Settings for Gear Surface Topography Corrections (DETC2011-47727) , 2012 .

[44]  Andrew Y. C. Nee,et al.  Towards a generic distributed and collaborative digital manufacturing , 2007 .

[45]  Clyde M. Creveling,et al.  Design for Six Sigma in Technology and Product Development , 2002 .

[46]  L. Zadeh.  Fuzzy sets as a basis for a theory of possibility , 1999 .

[47]  Faydor L. Litvin,et al.  Computerized generation and simulation of meshing and contact of spiral bevel gears with improved geometry , 1998 .

[48]  Mahmoud Houshmand,et al.  A collaborative and integrated platform to support distributed manufacturing system using a service-oriented approach based on cloud computing paradigm , 2013 .

[49]  Zhenyu Zhou,et al.  A hybrid modification approach of machine-tool setting considering high tooth contact performance in spiral bevel and hypoid gears , 2016 .

[50]  L. N. López de Lacalle,et al.  The Denavit and Hartenberg approach applied to evaluate the consequences in the tool tip position of geometrical errors in five-axis milling centres , 2008 .

[51]  Han Ding,et al.  Accurate nonlinear modeling and computing of grinding machine settings modification considering spatial geometric errors for hypoid gears , 2016 .

[52]  Li Pheng Khoo,et al.  Framework of a fuzzy quality function deployment system , 1996 .