Thesis (M.S.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1980. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND ENGINEERING. / Bibliography: leaves 89-90. / by Robert Allan Light. / M.S.

The increasingly competitive market is forcing the industry to develop higher-quality products more quickly and less expensively. Engineering analysis, at the same time, plays an important role in helping designers evaluate the performance of the designed product against design requirements. In the context of automated CAD/FEA integration, the domain-dependent engineers different usage views toward product models cause an information gap between CAD and FEA models, which impedes the interoperability among these engineering tools and the automatic transformation from an idealized design model into a solvable FEA model. Especially in highly coupled variable topology multi-body (HCVTMB) problems, this transformation process is usually very labor-intensive and time-consuming. In this dissertation, a knowledge-based FEA modeling method, which consists of three information models and the transformation processes between these models, is presented. An Analysis Building Block (ABB) model represents the idealized analytical concepts in a FEA modeling process. Solution Method Models (SMMs) represent these analytical concepts in a solution technique-specific format. When FEA is used as the solution technique, an SMM consists of a Ready to Mesh Model (RMM) and a Control Information Model (CIM). An RMM is obtained from an ABB through geometry manipulation so that the quality mesh can be automatically generated using FEA tools. CIMs contain information that controls the FEA modeling and solving activities. A Solution Tool Model (STM) represents an analytical model at the tool-specific level to guide the entire FEA modeling process. Two information transformation processes are presented between these information models. A solution method mapping transforms an ABB into an RMM through a complex cell decomposition process and an attribute association process. A solution tool mapping transforms an SMM into an STM by mimicking an engineers selection of FEA modeling operations. Four HCVTMB industrial FEA modeling cases are presented for demonstration and validation. These involve thermo-mechanical analysis scenarios: a simple chip package, a Plastic Ball Grid Array (PBGA), and an Enhanced Ball Grid Array (EBGA), as well as a thermal analysis scenario: another PBGA. Compared to traditional methods, results indicate that this method provides better knowledge capture and decreases the modeling time from days/hours to hours/minutes.

With the rise of automation in traditional manufacturing processes, more companies are beginning to integrate computer integrated manufacturing (CIM) cells on their production floors. Through CIM cell integration, companies have the ability to reduce process time and increase production. One of the problems created with CIM cell automation is caused by the dependency the sequential steps have on one another. Dependency created by the previous step increases the probability that a process error could occur due to previous variation. One way to eliminate this dependency is through the use of an in-process measuring device such as a Renishaw spindle probe used in conjunction with a computer numerical control (CNC) milling machine. Western Kentucky University (WKU) utilizes a CIM cell in the Senator Mitch McConnell Advanced Manufacturing and Robotics laboratory. The laboratory is located in the Architectural and Manufacturing Sciences department and gives students the opportunity to learn how automated systems can be integrated. The CIM cell consists of three Mitsubishi six-axis robots, a Haas Mini-mill, a Haas GT-10 lathe, an AXYZ, Inc. CNC router table, 120 watt laser engraver, an Automated Storage and Retrieval System (ASRS), material handling conveyor, and vision station. The CIM cell functions throughout the curriculum as a means for applied learning and research. The researcher used this CIM cell in order to determine if an in-process measuring device, such as the Renishaw spindle probe, had the ability to affect process capability. The researcher conducted the study to see if an in-process measuring device can be integrated into the CIM cell located in the Senator Mitch McConnell Advanced Manufacturing and Robotics laboratory to eliminate compounding variation. The researcher discovered that through the use of a Renishaw 40-2 spindle probe used in conjunction with a CNC Haas Mini Mill, process capability has the potential to be improved in a CIM cell by accounting for compounding variation present in the process.