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Multimedia Attachment to the Book “Manufacturing Technologies for Machines of the Future”

Multimedia Attachment to the Book “Manufacturing Technologies for Machines of the Future”. EXIT. Editorial Board of the Book. Prof. Pollmann W., Head of Editorial Board , Vice President Research, Materials and Production DaimlerChrysler AG, Germany.

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Multimedia Attachment to the Book “Manufacturing Technologies for Machines of the Future”

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  1. Multimedia Attachment to the Book “Manufacturing Technologies for Machines of the Future” EXIT

  2. Editorial Board of the Book Prof. Pollmann W., Head of Editorial Board, Vice President Research, Materials and Production DaimlerChrysler AG, Germany Academician, Prof. Frolow K. V., Director of the Mechanical Engineering Research Institute, Russian Academy of Sciences, Russia Prof. Dr. Sc. Dashchenko A. I., Head of Dept., Moscow State Technical University ”MAMI”, Russia Mr. Inaba H., Senior Vice-President of ”Fanuc” Ltd, Japan Prof. Dr.-Eng. Santochi M., Head of Section, University of Pisa, Italy • Prof. Dr.-Eng. Rehsteiner F., Head of the Institute of Machine Tools and • Manufacturing, Zurich University, Switzerland • Prof. Dr-Eng. habil. Peklenik J., Head of Department, University of • Ljubljana, Slovenia

  3. Manufacturing Technologies for Machines of the Future Prof. W. Pollmann

  4. Workgroup • 1. Prof. Dr. Sc. A.I. Dashchenko, Moscow State • Technical University <<MAMI>>, Russia • 2. Mr. W. Samlowski, DaimlerChrysler AG, Germany • 3. Prof. Dr. Sc. L.I. Volchkevich, Bauman TU, Russia • 4. Prof. Dr. Sc. E.G. Nachapetjan, Mechanical • Engineering Research Institute, Russian Academy • of Sciences, Russia • 5. Dr. O.A. Dashchenko, DaimlerChrysler AG, Russia • 6. Mr. H. Grosser, Fraunhofer Gesellschaft, Germany

  5. We thank the following companies for the permission to use their multimedia materials: -3D Systems, USA - Kuka Roboter GmbH, Germany - APS engineering, Germany - Hüller Hille, Germany Cross Hüller -Heinz-Nixdorf Institute,Germany - University of Pisa, Italy - DaimlerChrysler AG, Germany - Heidelberger Druckmaschinen, Germany - Fanuc Ltd, Japan - Autoplant ZIL, Russia - MSTU <<MAMI>>, Russia - IFW University of Hannover, Germany

  6. Multimedia Designers: Dr. Dudin E., NIITAvtoprom, Russia Dr. Dashchenko O., DaimlerChrysler AG, Russia

  7. Contents Part 1. Global Aspects of Manufacturing Part 2. Trends and Developments of Advanced Manufacturing: Scientific Basis Part 3.Trends and Developments of Advanced Manufacturing: Examples of Real Implementation Part 4. Advanced Manufacturing Equipment Part 5. Future Trends

  8. Part 1 Chapter 1. The Role of Mechanical Engineering in the 21st Century K.V. Frolov Chapter 2.Globalisation of production:Consequences of Product Design and Technology F. H. Rehsteiner Chapter 3. Fractal Company – a Revolution in Corporate Culture H. J. Warnecke Chapter 4. Adaptable Production Structures E. Westkaemper Chapter 5. Life Cycle Engineering S. K. Ong, A. Y. C. Nee

  9. Part 2 Chapter 6. Fundamental Points of Mechanical Engineering A. M. Dalsci, A. S. Vasiliev Chapter 7. High-speed Machining H. Schulz Chapter 8. Aspects of Manufacturing Systems’ Integration A. I. Dashchenko, W. Pollmann, O. A. Dashchenko Chapter 9. CAPP systems for Machining, Assembly and Disassembly Operations M. Santochi Chapter 10. Modeling of Machine Tools and Assembly Systems A. I. Dashchenko, W. Pollmann, O. A. Dashchenko Chapter 11.Cybernethic Structures, Networks and Adaptive Control of Work Systems in Manufacturing J. Peklenik

  10. Part 3 Chapter 12.Rapid Prototyping (RP) in Manufacturing F. H. Rehsteiner Chapter 13. Challenges in Electronic Production K. Feldmann Chapter 14. Electronic Vacuum Technologies L. I. Volchkevich, Y. I. Panfilov Chapter 15. New Solid-state Lasers and their Application Potentials H. Hügel Chapter 16. New Information Technologies in Industrial Activity of the Enterprises (IAE) R. Anderl Chapter 17. Modeling of Manufacturing and Technological Processes in CIM V. F. Gornev, V. V. Emelyanov, S. I. Iassinovski

  11. Part 4 Chapter 18.New Machine Tools and Systems M. Mandelli, T. Nagao, Y. Hatamura, M. Mitsuishi, M. Nakao, F. Rehsteiner Chapter 19. Reconfigurable Manufacturing Systems Y. Koren, U. Heisel, F. Jovane, T. Moriwaki, G. Pritschow, G. Ulsoy, H. Van Brussel Chapter 20. Robot Technology R. D. Schraft Chapter 21. Methods for Nondestructive Testing and Diagnostics of Automatic Equipment and Technological Systems of Machines N. N. Kluev, E. G. Nachapetjan, V. V. Sherbakov

  12. Part 5 Chapter 22.Prospects of Technologies Development H. Inaba Chapter 23. Perspectives of Innovative Technologies in Manufacturing J. Gausemeier

  13. Chapter 1 The role of mechanical engineering in the XXIst century The present state of engineering technologies on a global scale reflects primarily the progress made during the XXth century. Astonishing results and successes have been achieved in many respects, but there is also evidence of a growing number of negative by-products. Up to now progress in Mechanical Engineering has concentrated mainly on developing and improving the scientific basis and also on new design principles for yet more powerful and capable machinery and machine systems. The technical disciplines concerned most, are the structural, kinematic and dynamic analysis and synthesis of machines and machine systems for improved performance, safety aspects, tribology with special emphasis on friction and wear and improving machine resistance to the latter; understanding and avoiding the effects of vibrations and noise on people and on machinery, and, generally, improving the level of comfort and well being of the operators. K.V. Frolov To see CV click on the photo

  14. Chapter 1 The role of mechanical engineering in the XXIst century

  15. Konstantin FROLOV, Prof., Dr. Sc. (tech.), academician, vice-president of the USSR Academy of Sciences (1985-1992) and Russian Academy of Sciences (1992-1996) is an outstanding Russian scientist in the field of mechanical engineering, author of over 30 books and 800 papers, a founder of new scientific branches in biomechanics, nonlinear dynamics and safety of industrial objects. He achieved the highest Russian honors: several State Prizes, Government Awards (Gold Star of Labour Hero) and many orders and medals of the Russian Federation. His work is well-known in America, Europe, Japan and other countries. He is an honorable member of the American Society of Mechanical Engineering (ASME), the Swedish Royal Engineering Academy, the National Academy of Engineering (USA), the Royal Academy of Engineering (Great Britain) and of seven other National Academies, some of which have awarded him with Golden Medals for significant contribution in the Mechanical Engineering Sciences. K.V. Frolov

  16. Chapter 2 Globalisation of production: demands on products’ construction and technology In this chapter mostly the position of the manufacturer who is fully responsible for this product (the main contractor) is presented. The viewpoint of those carrying out the manufacturing, e.g., under subcontract, and of others interested in globalized production such as politicians and banks is not considered. F. H. Rehsteiner

  17. Fritz REHSTEINER, Prof., PhD., Dipl.-Eng., Act. Member of CIRP, Ass. Fellow AIAA Studies was during 9 years the Head of the Institute of Machine Tools and Manufacturing (IWF) at the Swiss Federal Institute of Technology (ETH), Zurich. • His Research Interests are: • Machine tools, primarily milling machines with special • attention to parallel kinematics machines (PKM) • Cutting processes • Aerodynamics • Astronomy • Prof. Rehsteiner is the author of approximately 20 publications in these research fields. F. H. Rehsteiner

  18. Chapter 3 Fractal company – a revolution in corporate culture To a large degree, it is possible to draw a parallel in the field of flexible production. The vision of large, highly complex and extremely flexible automatic production systems has not yet become reality. On the other hand, it is now commonplace within the metal processing industry for processing centres to employ an automated, operator-free exchange of tools and working materials during the third shift. This trend is reflected, too, in a drastic reduction in demand for consultancy services in recent years. The know-how formerly sought from external sources during the introduction of such systems, now constitutes part of standard expertise in engineering technology, even within a large number of medium-sized companies. H. J. Warnecke

  19. Hans-Juergen WARNECKE, Prof., Dr.-Eng., Dr. h. c. mult., President of the Fraunhofer Gesellschaft was born in 1934. He studied mechanical engineering at the ”Technische Hochschule” in Brunswick and was employed in engineering research. He became a Doctor of Engineering in 1963. Becoming a Professor in 197,1 he occupied the Chair of Industrial Manufacturing and Factory Operation at the University of Stuttgart, and also became head of the Fraunhofer Institute for Manufacturing Engineering and Automation IPA. Since 1993 Prof. Warnecke has been the President of the Fraunhofer Gesellschaft (Association for the Promotion of Applied Research) with its headquarters in Munich and from January 1995 until January 1998 - the President of the Association of German Engineers VDI. He has got numerous honours, including honorary doctorates from the Universities of Magdeburg, Ljubljana and Timisoara and the Distinguished Service Cross, 1st class, of the Federal Republic of Germany. H. J. Warnecke

  20. Chapter 4 Adaptable production structures Companies in processing industries operate today in a turbulent environment. This is mainly caused by technology, the globalization of markets and the permanent change in supply and demand. Effective survival strategies can only be developed if structures are adapted constantly. In this chapter strategies and methods contributing towards new dynamics will be discussed. The starting point of this article is the assessment of the adaptability of companies in this turbulent environment. The theme “adaptable production structures” is the subject of a long-term interdisciplinary fundamental research project at the University of Stuttgart in Germany, with the assistance of economical, technical and biotechnological institutes. E. Westkaemper

  21. Engelbert WESTKAEMPER, Univ.-Prof., Dr.-Eng., Prof. E.h., Dr.-Eng., E.h. Dr. h.c., since 1995 Director of the Institut für Industrielle Fertigung und Fabrikbetrieb (IFF) and Professor at the University of Stuttgart and Managing Director of the Fraunhofer Institut für Produktionstechnik und Automatisierung (IPA) in Stuttgart, was born in 1946, graduated in 1977 from the RWTH Aachen on the planning of flexible automated manufacturing systems. Before rejoining the University in 1988 as the Director of the Institut für Werkzeugmaschinen und Fertigungstechnik (IWF) and Professor at the Technische Universität Braunschweig, he worked for 12 years in the German aircraft (MBB) and electronics industry where he was responsible for the development, planning and introduction of new manufacturing methods and technologies, finally as Director and Head of the Central Department "Production Engineering" of AEG AG Frankfurt. E. Westkaemper

  22. Chapter 5 Life cycle engineering Life Cycle Engineering (LCE) refers to a relatively new approach in designing products that incorporates environmental issues and parameters across the entire life cycle of a product. LCE, the discipline of handling the new environmental parameters in product design, now has a strong hold in the manufacturing industry. It is the art of designing the product life cycle through choices about product concept, structure, materials and processes. The life cycle phases include pre-manufacture, manufacture, transportation/distribution, use and disposal of a product. In each phase, the choice of materials, processes, energy consumption, recyclability, etc., are carefully considered from the environmental viewpoint. A. Y. C. Nee S. K. Ong

  23. Andrew NEE Yeh Ching, Prof.,received his PhD from the Institute of Science and Technology, University of Manchester (UMIST) in 1973. He then joined the University of Singapore in 1974. In 1986 he was appointed as the Director of CAE/CAD/CAM Centre, when it was first established. In 1989 he was promoted to the full professorship. In 1990 he was elected as an Active Member of CIRP and a Fellow of the Society of Manufacturing Engineers. He was the first person in the Asian region to be elected in each case. From 1993 to 1996 worked as the Head of the Department of Mechanical & Production Engineering and then as the Dean of the Faculty of Engineering. Since 1998 he occupies two directors‘ positions at the university level: Director (Special Projects) of the Office of University Relations, and Director of the Office of Quality Management. Since 1999 he is heading the newly established Office of Admissions and since 2001 he is working as a Deputy Executive Director in the Science and Engineering Research Council (SERC) of the National Science and Technology Board. A. Y. C. Nee

  24. S.K.ONG received her B.Eng. (Honours in Mechanical Engineering) from the National University of Singapore in 1992. She obtained her PhD from the same University in 1996. Currently she is lecturing in the Manufacturing Division in the Department of Mechanical & Production Engineering. She is a member of the Society of Manufacturing Engineers and the Engineering Alumni Singapore. Now she is the program manager for the Virtual Manufacturing Program in the Laboratory for Concurrent Engineering and Logistics (LCEL) in the Faculty of Engineering. She is also active in the Academic Staff Social Committee, occupying the position of a staff advisor to the Faculty's Students Engineering Club, as well as the chairperson of the Student Self-Development Advisory Committee. S. K. Ong

  25. Chapter 6 Fundamentals of parts’ manufacturing The technology of machine-building manufacture represents a set of various technological processes — casting, forging, punching, heat treatment, painting etc. The technology of machine-building covers the final stages of machine-building manufacture — the work piece transformation into parts and assembly, i.e. the machine manufacturing. The practice of world engineering is characterized by the requirements to increase the products quality. The speeds, temperatures, accuracy and other parameters are augmented sharply. Involuntarily there is a problem: to what values the separate parameters can be increased, and others - decreased. The answer to this problem is not simple enough. A. M. Dalsci A. S. Vasiliev For additional multimedia material to this topic return please to the CD #1

  26. Chapter 6 Fundamentals of parts’ manufacturing

  27. Anton DALSCI, Prof.,Dr .Sc. (eng.) graduated from the Bauman Moscow Higher Technical School in 1949. For many years he has been working in the Department for Technology of Mechanical Engineering of the Bauman Moscow State Technical University. He is a merited worker of Science and Technology. Prof. Dalsci is the author ofover 120 publications in the field of Technology of precise Mechanical Engineering. A. M. Dalsci

  28. Alexandr VASILIEV, Prof., Dr. Sc. graduated from the Moscow Bauman Higher Technical School in 1972. He works in the Department for Manufacturing Engineering of the same Moscow State Technical University, which is now called Bauman. Prof. Vasiliev is the author ofmore than 60 publications in the field of precise Mechanical Engineering. A. S. Vasiliev

  29. Chapter 7 High Speed Machining High speed machining is an advanced production technology with great future potential. However, as it has been in many other realisations of the technological progress, the implementation of the fundamental knowledge into industrial products, has taken a relatively long time. In this particular case the period of approximately 60 years was not only due to a cautious attitude of the industry, but also to the fact that the existing production facilities corresponding to the state of the art, at the time when the first findings became available from research, did not meet the requirements of high-speed machining. H. Schulz For additional multimedia material to this topic return please to the CD #1

  30. Chapter 7 High Speed Machining Insert CD #2 and click here

  31. Chapter 7 High Speed Machining Chapter 7 High Speed Machining

  32. Chapter 7 High Speed Machining Insert CD #1 and click here

  33. Herbert SCHULZ, Prof., Dr.-Eng. was born in 1936, studied Mechanical Engineering at the Darmstadt University of Technology and received the title of Dr.-Eng. in Mechanical Engineering. Thereafter he worked as the Technical Sales Manager at Olivetti NC-Machines in Frankfurt, as the Head of Electro Heat Division at WC Heraeus in Hanau and then as the Executive Vice President at Scharmann GmbH & Co. in Mönchengladbach. In 1981 he became the Director of the Institute of Production Engineering and Machine Tools (PTW) of the Darmstadt University of Technology and in 1987 - the Dean of the Faculty of Mechanical Engineering of the Darmstadt University of Technology. He has a great amount of experience in high speed cutting technology, design of hsc-machine tools and components, development of special tools for high speed manufacturing and also in specific CAD/CAM systems. The scientific output of this research are 36 dissertations, 257 publications, appr. 260 papers and 4 books. H. Schulz

  34. Chapter 8 Aspects of manufacturing systems’ integration A. I. Dashchenko W. Pollmann O. A. Dashchenko This chapter presents research conducted within the field of modular manufacturing machine synthesis. The focus within this field lays in optimising technological processes of the initial stage. It is easier and less expensive to optimise a process in the initial stage than to alter finished equipment. The concept employs computer-aided search in the initial stages of process planning. This concept has already proved valid for mass and serial manufacturing. Therefore, it is being further developed to suit flexible manufacturing systems; the main goal thereby is to create cost-effective solutions for various types of manufacturing. For additional multimedia material to this topic return please to the CD #1 For additional multimedia material to this topic return please to the CD #1

  35. Chapter 8 Aspects of manufacturing systems’ integration

  36. Anatoly I. DASHCHENKO, Scientific Editor of this book,Merited Worker in Science and Engineering of Russia, Prof., Dr.-Eng., Dr. Sc., Head of the Department "Complex Automation in Machinebuilding” TU <<MAMI>>, Academician of International and Russian Academies of Electrotechnical Sciences, Member of Society of Automotive Engineers Inc. (N.Y.). was born in 1929. • The range of his scientific interests includes: • Theory and practice of complex automation of industry, based • on new technologies, • Problems of analysis and optimal synthesis of technological • machines and machine systems (incl. reconfigurable) designed • on the module principle, • New methods of calculation and experimental research of • productivity, accuracy of work of such systems, including • methods of statistical modelling. • He is the author of 19 books, more than 185 articles (60 of which are published in different international editions) and has 7 patents and inventions. A. I. Dashchenko

  37. Werner POLLMANN, Prof., Head of Editorial Board of this project was born in 1941 in Paderborn. After studying mechanical engineering at the University of Hannover he worked as an assistant to the Chair of Design at the University of Stuttgart. In 1969 he joined DaimlerChrysler. After several years in the field of Manufacturing and Engineering, Prof. Pollmann became Senior Vice President for Production and Material Research and Chief Environmental Officer in 1990. In 1995 he was appointed Professor of Construction and Manufacturing at the University of Stuttgart. W. Pollmann

  38. Oleg A. DASHCHENKO, Manager of this book-project, Dr.-Eng., researcher at the DaimlerChrysler AG, was born in 1962 and graduated from the Moscow State Technical University <<MAMI>> in 1985. After several years of practical work as the development engineer he finished his PhD in the field of assembly automation. Since 1993 has been working as a researcher at DaimlerChrysler. • The range of his scientific interests includes: • Theory and practice of assembly automation in automotive industry; • New assembly, machining and internal combustion engine technologies. • He is the author of 6 patents (4 of them joint international patents) and of about 12 articles in different European editions. O. A. Dashchenko

  39. Chapter 9 CAPP systems for machining, assemblyand disassembly This chapter discusses some issues regarding the application of CAPP (Computer-aided Process Planing) systems in the fields of machining, assembly and disassembly. A few examples of successfully tested CAPP systems, are presented and discussed. Some conclusions on the future predictable developments of CAPP systems are finally drawn. M. Santochi For additional multimedia material to this topic return please to the CD #1

  40. Marco SANTOCHI, full Professor of manufacturing engineering at the Faculty of Engineering of the University of Pisa since 1990. He occupies the position of the Head of the Department of Production Engineering at the University of Pisa and now he is the Head of the Production section of the Department of Mechanical, Nuclear and Production Engineering. His research activity carried out in various areas like sensors for cutting process monitoring, adaptive controls for machine tools, CAPP, automated assembly, recycling of used consumer products. Prof. Santochi is an active member of CIRP with the role of the Technical Secretary and Chairman of the STC Assembly, Member of SME (Society of Manufacturing Engineers), responsible of a national research project on CAPP, responsible of the monitoring of the National Research Project on Industrial Design, Expert Assessor at the EC for research projects. M. Santochi

  41. Chapter 10 Results of machine-tool and assembly systems’modelling NEXT VIDEO

  42. Chapter 10 Results of machine-tool and assembly systems’modelling NEXT VIDEO

  43. Chapter 10 Results of machine-tool and assembly systems’modelling

  44. Chapter 10 Results of machine-tool and assembly systems’modelling A. I. Dashchenko W. Pollmann O. A. Dashchenko Statistical simulation is used to analyse complex manufacturing systems (MS). The method is based on the statistical laws of technical systems. Statistical simulation can be applied in varied situations. For example, one could apply statistical simulation when analysing machine-tools or assembly lines. The question is, should one analyse machine-tool/assembly lines using statistical simulation? When working positions/machine tools in an area are connected by rigid transports, the main parameters of such blocked-together "simple" systems can be evaluated using elementary formulae. A model of a blocked-together system is examined in this work at a later time. For additional multimedia material to this topic return please to the CD #1 For additional multimedia material to this topic return please to the CD #1

  45. Chapter 10 Results of machine-tool and assembly systems’modelling

  46. Chapter 11 Cybernetic structures, operations and control of work systems in manufacturing This contribution presents some thoughts about the importance of the Cybernetics, the new scientific discipline, developed by N. Wiener, on the manufacturing science and technology. The foundation of the approach is the Elementary Work System (EWS). It is analysed from the cybernetic and information viewpoint. The subject’s competence, as a decisive factor for structuring, operating and controlling the EWS is discussed in detail. The influence of the human factors on the competence is explained. The control of EWS should consider the information as well as the cybernetic laws. The conventional factory system and an EWS adaptive network are briefly discussed J. Peklenik

  47. Janez PEKLENIK, Prof., Dr.Eng., habil. was born in 1926 and is now working as the Head of Department of Control and Manufacturing Systems at the University of Ljubljana. He is also the President of the Engineering Academy of Slovenia and Fellow of the International Institution for Production Engineering Research (CIRP). In 1979/80 he was the President of CIRP. • His research interests are: • Online identification of manufacturing processes (cutting, • grinding), • Adaptive control, • Automation of manufacturing systems, • Surface charactirisation, • CA/group technology, • Generative CAPP, • Complex systems in manufacturing. • Prof. Peklenik is the author of more then 220 publications and 11 patents. J. Peklenik

  48. Chapter 12 Rapid Prototyping (RP) in Manufacturing Rapid Prototyping is the name for a group of novel part manufacturing processes relying on the quick solidification of a loose material. They are supposed to be faster and more flexible than conventional techniques and therefore suited particularly for producing prototypes in a very short time. F. H. Rehsteiner For additional multimedia material to this topic return please to the CD #1 For additional multimedia material to this topic return please to the CD #1

  49. Chapter 13 Challenges in electronic production Increasing demands referring to the quality and the functionality of electronic systems have contributed to a growing diversity of component packages. Therefore the Surface Mount Devices (SMD) have, except components for high power and high mechanical strain (plugs, sockets, etc.), replaced devices in Through Hole Technology (THT). K. Feldmann

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