KNOWLEDGE BASED SYSTEM FOR DESIGN/SELECTION OF BENDING DIE COMPONENTS

Presented 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.
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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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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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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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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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Wiping bending die

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Exploded View of Bending Die -

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Bending die components

Die block A die block is a construction

component that houses the opening and receives punches. Material Tool Steel
Punch plate Similar to die block used to hold and

support the punch. Material Hardened Tool Steel

11 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).
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 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 steel
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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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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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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.
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Architecture of Expert System

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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 enhancements
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 Problem Identification and feasibility analysis

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.
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 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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 Complete and Field the ES -

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.
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Development Procedure of Expert System for bending die design

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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 >
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 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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 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

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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 twofold

1. 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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Literature Review
Sr. Researcher No
1 Uzsoy, et. al., (1991)

System Details
Rule based KBC implemented using turbo prolog.

Remarks
A 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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Sr. No Researcher
6 Inamdar, M. et al. (2000) Ching, Z. (2001) Shigeru, A. et al. (2002)

System Details
Artificial 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

Remarks
More 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.

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)

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Sr. No
11

Researcher
Rico, 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

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Sr. No
17

Researcher
Bozdemir, M. et al. (2008) Kazan, R. et al. (2009) Kontolatis, N. et al. (2010)

System Details
ANN for Springback in V-Bending ANN for springback in wipe bending Optimization of Bending Process planning parameters

Remarks
Good 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

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TENTATIVE RESEARCH PLAN FOR NEXT SEMESTER

Months Activity
Dec. 2012

Jan. Feb. 2013 2013

Marc April May June h 2013 2013 2013 2013

Regular visits to Industries Develop ment of modules

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Thank
You.

KNOWLEDGE BASED SY3STEM FOR DESIGN/SELECTION OF

2/16/13