Semantic interoperability (SI) of a product model refers to automatic exchange of meaning associated with the product data, among applications/domains throughout the product development cycle. In the product development cycle, several applications (engineering design, industrial design, manufacturing, supply chain, marketing, maintenance etc.) and different engineering domains (mechanical, electrical, electronic etc.) come into play making the ability to exchange product data with semantics very significant. With product development happening in multiple locations with multiple tools/systems, SI between these systems/domains becomes important. The thesis presents a feature-based framework for shape model to address these SI issues when exchanging shape models. Problem of exchanging semantics associated with shape model to support the product lifecycle has been identified and explained. Different types of semantic interoperability issues pertaining to the shape model have been identified and classified. Features in a shape model can be associated with volume addition/subtraction to/from base-solid, deformation/modification of base-sheet/base surface, forming of material of constant thickness. The DIFF model has been extended to represent, classify and extract Free-Form Surface Features (FFSFs) and deformation features in a part model. FFSFs refer to features that modify a free-form surface. Deformation features are created in constant thickness part models, for example, deformation of material (as in sheet-metal parts) or forming of material (as in injection molded parts with constant thickness), also referred to as constant thickness features. Volumetric features covered in the DIFF model have been extended to classify and represent volumetric features based on relative variations of cross-section and PathCurve. Shape feature ontology is described based on unified feature taxonomy with definitions and labels of features as defined in the extended DIFF model. Features definitions are used as intermediate and unambiguous representation for shape features. The feature ontology is used to capture semantics of shape features. The proposed ontology enables reasoning to handle semantic equivalences between feature labels, and is used to map shape features from a source to target applications. Reasoning framework for identification of semantically equivalent feature labels and representations for the feature being exchanged across multiple applications is presented and discussed. This reasoning framework is used to associate multiple construction paths for a feature and associate applicable meanings from the ontology. Interface is provided to select feature label for a target application from the list of labels which are semantically equivalent for the feature being exchanged/mapped. Parameters for the selected feature label can be mapped from the DIFF representation; the feature can then be represented/constructed in the target application using the feature label and mapped parameters. This work shows that product model with feature information (feature labels and representations), as understood by the target application, can be exchanged and maintained in such a way that multiple applications can use the product information as their understandable labels and representations. Finally, the thesis concludes by summarizing the main contributions and outlining the scope for future work.

Articular cartilage covers the articulating ends of diarthrodial joints. It plays a vital role in the function of the musculoskeletal system by allowing almost frictionless motion to occur between the articular surfaces of a diarthrodial joint. Study of cartilage contact behavior will help to understand the intrinsic biomechanical properties related to cartilage degeneration and related pathology. In order to study the mechanical behavior of the cartilage a FEM based computational model of the knee-joint was developed from MRI data. A heuristic algorithm was developed based on Image processing techniques using Evolve2D toolbox and edge detection. An indigenous path following algorithm to capture minute details of bone and soft tissue curvature was developed using Image Processing Toolbox of Matlab. Parts including femur, tibia, femoral and tibial cartilages, lateral & medial menisci were extracted as a point cloud from each of the slices and rendered into a 3D model using GUI driven CAD package RHINOCEROS 4.0. Commercial FE software HYPERMESH 9.0 was used to develop FE model from geometric model. Cartilage and Menisci were modeled using eight node hexahedral elements and bones were modeled using four node quadrilateral elements. Bones were assumed to be rigid. Cartilage and menisci were assumed to be linearly elastic, isotropic and homogenous. The knee joint was subjected to a uniaxial compressive load with tibia remaining fixed and femur subjected to two primary boundary conditions: 1.Flexion - extension and Varus - Valgus rotation constrained; 2.Only Varus - Valgus rotation constrained. Parameters such as contact area, contact pressure, contact force, centre of contact pressure, mises stress distribution; maximum and minimum principal stresses were studied at maximum compressive load condition and also in intermittent steps. This model considered both geometric and contact non-linearity. From the FE analysis, it was observed that peak contact deformation and contact area on both femoral and tibial medial cartilage was found to be greater than the lateral side under full extension condition. More than 50% of the load transmission was through the medial side - which could be an indication of cartilage degeneration. Deformation of lateral meniscus was more than the medial meniscus under angular constrained conditions. Loading history during intermittent steps suggested that contact area on lateral tibial cartilage increased with load, indicating joint asymmetry. These results indicate the importance of the rotational constraints (boundary conditions) and represent more accurate physiological behavior of knee joint. Role of menisci in this study was analyzed, which indicated that consideration of menisci is essential in biomechanical estimation of load transmission. In conclusion, detailed segmentation to develop geometric model, precise boundary conditions & time dependent behavior of cartilage and menisci helped in understanding knee joint load bearing capacity to a better accuracy and can potentially give rise to designing better cartilage implants.

Product life cycle (PLC) is the cycle which every product goes through from introduction to eventual demise. There are several issues with the current life cycle of a product when looked from the environmental impact perspective. These are: 1) depletion of natural resources due to the use of virgin materials for production, 2) Consumption of substantial amounts of energy during manufacturing, assembly and use, and 3) production of large amounts of waste during the lifecycle including those at the End of Life (EoL) phase. These issues impact resource scarcity, adverse effects on the environment and loss of embodied energy as waste. Some of the potential solutions to these issues, as proposed in literature, are: to recycle, reuse and remanufacture products in order to reclaim materials, components and sub-assemblies from used products and make them available for new products. In order to efficiently carry out these recovery processes, a pre-requisite is disassembly. Product disassembly is defined as the processes of systematic removal of desirable constitute parts from an assembly while ensuring that there is no impairment of the parts due to the disassembly process. The following are the major research issues in the field of disassembly. One is the conflict between environmental and economic goals, i.e. as to which should be targeted at in disassembly objectives. These conflicts lead to abandoning non-destructive disassembly techniques so as to favour the profit objective. The other issues, prevalent during EoL phase, are: corrosion due to use, less residual value in the parts, complicated structure and intricacy in parts, which together make non-destructive disassembly a task difficult for automation. This means that disassembly processes have to be carried out by human operators. The manual disassembly processes are effort intensive and pose ergonomic risks to the human operators involved in disassembling. The nature of ergonomic risks and effort spent in disassembly is influenced by the efficiency of disassembly operation. However, little research has been carried out to address the above factors of effort, profit, efficiency, environment and ergonomic risk during disassembly in an integrated manner. These factors form the major motivations for the research work carried out in this thesis. A series of empirical studies have been undertaken to assess these factors and their impact on product disassembly. The studies focus on disassembly processes for consumer electronic products in two major recycling sectors in developing countries, leading to development of metrics with which the above factors can be assessed individually and traded off in an integrated manner during the early design stages of a product. These metrics should help designers understand and improve the major disassembly aspects of a product during designing and help prevent major disassembly problems at the EoL phase while improving efficiency of recovery options. The objective of this thesis, therefore, is to develop an Integrated Framework for supporting decision making during early stages of design to improve disassembly during the EoL phase of the product. The framework is intended to help in evaluating alternative designs for easy (less effort), profitable, efficient and environment-friendly disassembly at the EoL phase of the product life cycle. The Framework constitutes new measures developed for supporting decision making on above aspects of disassembly during the early stage of designing. The Framework has been implemented into a computer based tool called ‘IdeAssemble’ and evaluated for its functionality with the help of a design experiment. The tool can be used at the embodiment stage of the design phase, when on an exploded view of the product, with information on its materials, geometry, disassembly tools and types of disassembly task are available to the designer.

National Programme on Micro and Smart Materials and Systems (NPMASS) / A computer-aided technique is developed in this thesis to systematically generate concepts for sensors of a wide variety. A database of building blocks, based on physical laws and effects that capture the transduction rules underlying the working principles of sensors, has been developed to synthesize concepts. The proposed method uses the database to first create a concept-space graph and then selects concepts that correspond to paths in the graph. This is in contrast to and more efficient than existing methods, such as, compositional synthesis and graph-grammar synthesis, where solution paths are laid out first and then a concept-space graph is generated. The research also explores an approach for synthesis of concepts for closed-loop sensors, where a quantity is sensed indirectly after nullifying its effect by using negative feedback. These sensors use negative feedback to increase the dynamic range of operation without compromising the sensitivity and resolution. According to the literature, generation of un-interesting solutions is a major drawback of the building block-based synthesis approaches. In the proposed approach, this shortcoming is mitigated substantially by using some rules. For a number of the concepts generated, in the sensor problems attempted, we found that those concepts were already implemented in existing patents; thus emphasising the usefulness of the concepts produced. The synthesis approach proposed new, feasible sensor concepts, thereby indicating its potential as a stimulator for enhancing creativity of designers. Another important problem is to improve the robustness of designs. Robustness can be achieved by minimizing the side effects. Side effects are defined as unwanted effects that affect the intended working of the sensor. The research presents an algorithm that (a) predicts the potential side effects for the synthesized concepts of sensors; (b) aids in quantifying the magnitude of the side effects, thus helping the designer to predict the significant side effects; and (c) suggests ways to improve the robustness of the design.

[pt] A necessidade de aumentar a produtividade no setor da construção civil estimulou investimentos em soluções digitais e a incorporação de princípios de manufatura na cadeia construtiva. A implementação de elementos estruturais padronizados fabricados fora do canteiro de obra é considerada uma prática válida para atingir este objetivo. O projeto para fabricação e montagem é um conceito que envolve diretrizes a serem consideradas no desenvolvimento do projeto, cuja finalidade é facilitar a fabricação e montagem de componentes. A metodologia BIM pode incorporar análises de planejamento e construtibilidade para apoiar a tomada de decisão no contexto de construções replicáveis em escala de concreto armado. A presente investigação inclui uma revisão sistemática da literatura que orientou a pesquisa. Com base na SLR (Structured Literature Review), foi desenvolvido um Manual de Entrega de Informações que propõe um novo fluxo de trabalho no qual os estudos de planejamento construtivo e princípios de fabricação e montagem são agregados nos estágios iniciais do projeto para aproveitar a colaboração intrínseca da metodologia BIM. Para ilustrar o fluxo de trabalho proposto no IDM (Information Delivery Manual) desenvolvido é apresentado um experimento de um complexo de escolas. As informações do modelo parametrizado serviram como dados de entrada para as análises realizadas permitindo assim que pudessem ser comtemplados diferentes cenários de soluções estruturais. Os resultados obtidos pelo experimento indicam que a consideração de elementos de concreto pré-fabricado nem sempre vai contra os interesses econômicos, práticos e estéticos. Por fim, as análises de planejamento e construtibilidade são parâmetros importantes nas tomadas de decisão para aprimorar a identificação de oportunidades de melhorias no projeto e potencializar a eficiência de trabalho no canteiro de obra. / [en] The need to increase the civil construction sector stimulates investments in digital solutions and manufacturing principles in construction industry. The employment of standardized structural elements manufactured off-site construction, such as structural precast element, is considered a valid practice to achieve this purpose. The Design for Manufacturing and Assembly (DFMA) is a concept that involves guidelines considered in the development of the project and has the objective to facilitate the manufacturing and assembly of a product or component. Building Information Modeling (BIM) methodology can incorporate planning and constructability analysis to support decision making in the context of scalable and replicable concrete building projects. The present investigation includes a Structured Literature Review (SLR) that guided the research. Based on the SLR, an Information Delivery Manual (IDM) was developed to propose a new workflow in which the studies of construction planning and the application of manufacturing and assembly principles are considered in the early stages of design to take advantage of the collaboration intrinsic to the BIM methodology. An experiment of a school complex is presented to illustrate the workflow proposed in the developed IDM. The parametric model information was the key input to run analyzes in different structural solutions scenarios. The results indicated that the consideration of precast concrete elements does not always contradict economic, practical and aesthetic interests. Finally, planning and constructability analyzes are important parameters in decision-making, enhancing the recognition of opportunities for improvement in the project and increasing the efficiency of work in the construction site.

A pragmatic method for selecting components and devices from a database or parameterized models is developed in this thesis. The quantitative framework presented here is sufficiently general to accommodate an entire device assembly, a component, or a sub-assembly. The details pertaining to a device or a component are classified into three sets of variables: (i) user-specifications, s (ii) device parameters, p , and (iii) device characteristics, c . Functional, practical, and performance-related attributes that a user can provide comprise user-specifications. Since, most often, a specification cannot be specified as a single number, we allow the user to enter a range with lower and upper bounds. Device parameters comprise the geometry and material properties, and device characteristics include functional requirements and performance criteria. Thus, for a device, all its functional and utility attributes are contained in the union of sets s and c , whereas the geometry and the material properties are in set p . The equations governing the physical behavior of the device are written in terms of s , p , and c . These equations may sometimes be readily available; when they are not, it may be necessary to formulate them as required. By solving the governing equations along with the inequalities that arise from the lower and upper bounds on s , we obtain feasible ranges on p and c . Then, for any pair of device characteristics, a 2D feasible map is drawn, to visually portray the consequences of user-specifications. If the feasible map is null, small, or large, it indicates that the user-specifications are infeasible, stringent, or there is much scope for design, respectively. This can be inferred even before the designs are considered. Juxtaposed on the feasible map are points or lozenges corresponding to the quantitative attributes of the entries in the database. The ones that lie inside the feasible map can be reckoned as meeting the user-specifications and thus, enabling selection. On the other hand, if there is no database or none of the devices in the database lie inside the feasible map, we can identify the feasible ranges of all the design parameters for every point inside the feasible map. This information is useful to the designer to redesign and arrive at feasible designs by using parameterized models of the device. A Graphical User Interface (GUI) is developed to facilitate the user-interaction. The utility of the selection framework is demonstrated with a variety of case-studies including miniature pumps, heat pulse-based soil-moisture sensors, springs, flywheels, compliant mechanisms, micromechanical suspensions, etc. The latter two use kineto-elastic characteristics of deformable components. The framework, when used for materials selection, can be seen as an extension of Ashby’s materials selection method. This is also illustrated with two examples.

La « conception pour la fabrication » ou DFM (Design for Manufacturing) est une méthode maintenant classique pour assurer lors de la conception des produits simultanément la faisabilité, la qualité et le rendement de la production. Dans l'industrie microélectronique, le Design Rule Manual (DRM) a bien fonctionné jusqu'à la technologie 250nm avec la prise en compte des variations systématiques dans les règles et/ou des modèles basés sur l'analyse des causes profondes, mais au-delà de cette technologie, des limites ont été atteintes en raison de l'incapacité à sasir les corrélations entre variations spatiales. D'autre part, l'évolution rapide des produits et des technologies contraint à une mise à jour « dynamique » des DRM en fonction des améliorations trouvées dans les fabs. Dans ce contexte les contributions de thèse sont (i) une définition interdisciplinaire des AMDEC et analyse de risques pour contribuer aux défis du DFM dynamique, (ii) un modèle MAM (mapping and alignment model) de localisation spatiale pour les données de tests, (iii) un référentiel de données basé sur une ontologie ROMMII (referential ontology Meta model for information integration) pour effectuer le mapping entre des données hétérogènes issues de sources variées et (iv) un modèle SPM (spatial positioning model) qui vise à intégrer les facteurs spatiaux dans les méthodes DFM de la microélectronique, pour effectuer une analyse précise et la modélisation des variations spatiales basées sur l'exploitation dynamique des données de fabrication avec des volumétries importantes. / The DFM (design for manufacturing) methods are used during technology alignment and adoption processes in the semiconductor industry (SI) for manufacturability and yield assessments. These methods have worked well till 250nm technology for the transformation of systematic variations into rules and/or models based on the single-source data analyses, but beyond this technology they have turned into ineffective R&D efforts. The reason for this is our inability to capture newly emerging spatial variations. It has led an exponential increase in technology lead times and costs that must be addressed; hence, objectively in this thesis we are focused on identifying and removing causes associated with the DFM ineffectiveness. The fabless, foundry and traditional integrated device manufacturer (IDM) business models are first analyzed to see coherence against a recent shift in business objectives from time-to-market (T2M) and time-to-volume towards (T2V) towards ramp-up rate. The increasing technology lead times and costs are identified as a big challenge in achieving quick ramp-up rates; hence, an extended IDM (e-IDM) business model is proposed to support quick ramp-up rates which is based on improving the DFM ineffectiveness followed by its smooth integration. We have found (i) single-source analyses and (ii) inability to exploit huge manufacturing data volumes as core limiting factors (failure modes) towards DFM ineffectiveness during technology alignment and adoption efforts within an IDM. The causes for single-source root cause analysis are identified as the (i) varying metrology reference frames and (ii) test structures orientations that require wafer rotation prior to the measurements, resulting in varying metrology coordinates (die/site level mismatches). A generic coordinates mapping and alignment model (MAM) is proposed to remove these die/site level mismatches, however to accurately capture the emerging spatial variations, we have proposed a spatial positioning model (SPM) to perform multi-source parametric correlation based on the shortest distance between respective test structures used to measure the parameters. The (i) unstructured model evolution, (ii) ontology issues and (iii) missing links among production databases are found as causes towards our inability to exploit huge manufacturing data volumes. The ROMMII (referential ontology Meta model for information integration) framework is then proposed to remove these issues and enable the dynamic and efficient multi-source root cause analyses. An interdisciplinary failure mode effect analysis (i-FMEA) methodology is also proposed to find cyclic failure modes and causes across the business functions which require generic solutions rather than operational fixes for improvement. The proposed e-IDM, MAM, SPM, and ROMMII framework results in accurate analysis and modeling of emerging spatial variations based on dynamic exploitation of the huge manufacturing data volumes.

Fiber-reinforced composites comprise an important class of lightweight materials which are finding increasing applications in engineering structures including body components of automobiles and aircraft. Traditionally, synthetic fibers made of glass, carbon, etc. along with a polymeric resin have constituted the most common composites. However, due to environmental concern, occupational health safety considerations, higher cost, etc., research has been focused on substituting synthetic fibers, especially glass fibers with safer, economic and biodegradable natural fibers. Due to the ease of availability and affordability in terms of cost, woven jute mats, among a wide variety of natural fiber-based reinforcements, offer a good choice in combination with a suitable resin such as polyester or epoxy for fabrication of composite laminates. In structural applications, joining of parts made of jute fiber-reinforced composites (JFRCs) would be a natural requirement. Alternatives to joining processes for metals such as welding, riveting, etc. are required for composites. A joining process of high potential is adhesive bonding which has the advantages of reducing stress concentration, permitting fastening of dissimilar materials, etc. In the present study, adhesively bonded joints of JFRCs and their mechanical behavior are investigated under quasi-static and cyclic loading conditions. Initially, characterization of substrates is carried out under monotonic loading. This is followed by determination of stress- Strain curves, failure load and mean shear strength of bonded joints as functions of joint curing temperature and overlap length using a two-part structural epoxy adhesive. All tests are carried out according to relevant ASTM standards. It has been observed that higher curing temperatures give rise to only marginally high failure load and mean shear stress at failure compared to curing at room temperature. For a given curing temperature, failure load increases while mean shear strength decreases with respect to overlap length in both types of joints. As fatigue failure is a crucial consideration in design, the behavior of adhesively bonded JFRC joints is studied for the first time under cyclic loading conditions leading to the commonly-used S-N curve for characterization of failure of materials at different loading-unloading cycles. Interestingly, the fatigue strength for infinite life of adhesively bonded JFRC joints turns out to be approximately 30% of the quasi-static strength, a correlation which usually applies to materials in general. The effect of joint overlap length on fatigue life is studied and it is observed that the above relation between fatigue and quasi static strength is retained for different overlap lengths. Additionally, insights are provided into failure modes of joints under different loading conditions and for varying overlap lengths. Various empirical predictors such as exponent, power and hybrid models fitting the S-N curve are obtained and their relative efficacy (in terms of Coefficient of Determination R2, Adjusted-R2, Akaike’s Information Criterion and Residual Sum of Squares) enumerated in prediction of failure load including quasi-static failure load. As numerical simulation is an indispensable tool in designing geometrically complex structures under nonlinear conditions including failure and contact, finite element modeling of JFRC substrates, bulk adhesive and adhesively bonded joints has been investigated using implicit and explicit LS-DYNA solvers. In this context, the effects of various modeling parameters (mesh size and loading rate) and details of constitutive models capable of capturing plasticity and failure in an orthotropic composite and isotropic adhesive are discussed. Mesh size has been found to be an important parameter affecting computed results. Finally, a good correlation within ~(4% - 7%) was found between the predicted and experimental results for JFRC substrates, bulk adhesive and adhesively bonded single lap joints.

The focus of the present work is natural human like grasping, for realistic performance simulations in digital human modelling (DHM) environment. The performance simulation for grasping in DHM is typically done through high level commands to the digital human models (DHMs). This calls for a natural and unambiguous scheme to describe a grasp which would implicitly accommodate variations due to the hand form, object form and hand kinematics. A novel relational description scheme is developed towards this purpose. The grasp is modelled as a spatio-temporal relationship between the patches (a closed region on the surface) in the hand and the object. The task dependency of the grasp affects only the choice of the relevant patches. Thus, the present scheme of grasp description enables a human like grasp description possible. Grasping can be simulated either in an interactive command mode as discussed above or in an autonomous mode. In the autonomous mode the patches have to be computed. It is done using a psychological concept, of affordance. This scheme is employed to select a tool from a set of tools. Various types of grasps a user may adopt while grasping a spanner for manipulating a nut is simulated. Grasping of objects by human evolves through distinct naturally occurring phases, such as re-oreintation, transport and preshape. Hand is taken to the object ballpark using a novel concept of virtual object. Before contact establishment hand achieves the shape similar to the global shape of the object, called preshaping. Various hand preshape strategies are simulating using an optimization scheme. Since the focus of the present work is human like grasping, the mechanism which drives the DHMs should also be anatomically pertinent. A methodology is developed wherein the hand-object contact establishment is done based on the anatomical observation of logarithmic spiral pattern during finger flexion. The effect of slip in presence of friction has been studied for 2D and 3D object grasping endeavours and a computational generation of the slip locus is done. The in-grasp slip studies are also done which simulates the finger and object response to slip. It is desirable that the grasping performance simulations be validated for diverse hands that people have. In the absence of an available database of articulated bio-fidelic digital hands, this work develops a semi-automatic methodology for developing subject specific hand models from a single pose 3D laser scan of the subject's hand. The methodology is based on the clinical evidence that creases and joint locations on human hand are strongly correlated. The hand scan is segmented into palm, wrist and phalanges, both manually and computationally. The computational segmentation is based on the crease markings in the hand scan, which is identified by explicitly painting them using a mesh processing software by the user. Joint locations are computed on this segmented hand. A 24 dof kinematic structure is automatically embedded into the hand scan. The joint axes are computed using a novel palm plane normal concept. The computed joint axes are rectified using the convergence, and intra-finger constraints. The methodology is significantly tolerant to the noise in the scan and the pose of the hand. With the proposed methodology articulated, realistic, custom hand models can be generated. Thus, the reported work presents a geometric framework for comprehensive simulation of grasping performance in a DHM environment.

Natural fiber-reinforced composites are now finding extensive uses in various fields from household articles to automobiles. These composites can score high compared to common synthetic fiber-based composites, notably glass fiber-reinforced composites, in areas such as occupational safety and health, and impact on environment. The current research work is motivated by the need for exploring jute fibers as replacement for glass fibers for various engineering design applications including more demanding impact protection applications as in automotive body structures. In the current work, detailed mechanical characterization of jute-polyester (JP) composite laminates till failure has been carried out for tensile, compressive and flexural loads by varying volume fraction of jute fibers. The effect of fiber volume fraction on mechanical properties is shown. Because of the potency of closed thin-walled components as structural energy-absorbers, a comprehensive experimental study has been performed, for the first time, comparing the behaviors of various geometric sections of JP and glass-polyester (GP) composite tubes under axial quasi-static and low velocity impact loading. Additionally, for jute-reinforced plastic panels to be feasible solutions for applications such as automotive interior trim panels, laminates made of such materials should have adequate perforation resistance. Thus, a detailed comparative study has been carried out for assessing the performance of JP laminates vis-a-vis GP plates under low velocity impact perforation conditions. As high-end product design is heavily driven by CAE (Computer-Aided Engineering), the current research work has also focused on the challenging task of developing reliable modeling procedures for explicit finite element analysis using LS-DYNA for predicting load-displacement responses and failures of JP composites under quasi-static and impact loading conditions. In order to extend the applications of JP composites to structurally demanding applications, hybrid laminates made of jute-steel composites and jute with nanoclay-reinforced polyester have been investigated and the considerable enhancement of mechanical properties due to hybridization is shown. Furthermore, a comprehensive study has been conducted on the behavior of JP laminates for varying degrees of moisture content until saturation, and the efficacy of hybrid laminates in this context has been shown.