Configurable software systems adapt to changes in hardware and execution environments, and often exhibit a variety of complex maintenance issues. Many tools exist to aid developers in analysing and maintaining large configurable software systems. Some are standalone applications, while a growing number are becoming part of Integrated Development Environments (IDE) like Eclipse. Reusable tooling frameworks can reduce development time for tools that concentrate on software configuration analysis. This thesis presents C-CLEAR, a common, reusable, and extensible tooling framework for software configuration analysis, where clear separation of concern exists between tooling functionality and definitions that characterise a software system. Special emphasis will be placed on common mechanisms for data abstraction and automatic IDE integration independent of the software system that is being analysed. / Graduate

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Published Article / In this paper the time and cost parameters of tooling manufacturing by metal casting in rapid prototyping sand moulds are assessed and comparison is made with alternative tool making processes such as computer numerical control machining and investment casting (Paris Process). To that end two case studies obtained from local companies were carried out. The tool manufacturing was conducted according to a five steps process chain referred to as Rapid Casting for Tooling (RCT). These steps include CAD modelling, casting simulation, rapid prototyping, metal casting and finishing operations. In particular the Rapid Prototyping (RP) step for producing the sand moulds was achieved with the aid of an EOSINT S 550 Laser Sintering machine and a Spectrum 510 Three Dimensional Printer. The results indicate that RP is the rate determining step and cost driver of the proposed tooling manufacturing technique. In addition it was found that this tool making process is faster but more expensive than machining and investment casting.

Published Article / This paper surveys the current state and capabilities of Three Dimensional Printing (3DP). Based on its technical background - the ink jet printing as known from the printer and plotter industry - a classification structure has been developed and proposed. Different printing techniques and process concepts, together with their advantages and limitations are described and analysed. A large variety of manufacturing applications such as rapid pattern making and rapid tooling using the 3DP process directly or as core technology, as well as further implications in design and engineering analysis, medicine, and architecture are presented and evaluated. Some research issues are also discussed. An attempt, based on the state of the art, to show weaknesses and opportunities, and to draw conclusions about the future of this important process wraps up this paper.

Published Article / Global issues such as energy and climate changes have impacted on both the automotive and aerospace industries, forcing them to adopt measures to produce products that consume fewer combustibles and emit less carbon dioxide. Making vehicles lighter is one of the logical ways of reducing fuel consumption. The need for light components, able to fulfil technical and quality specifications, led to market growth for tooling that is able to mass produce parts using manufacturing processes such as high pressure die casting. Competitive pressures to reduce the lead time required for tooling-up has also increased dramatically. For this reason research into various methods, techniques and approaches to tool manufacture is being undertaken globally. This paper highlights the work undertaken at the CSIR on the issue of rapid die manufacturing through the application and evaluation of a rapid prototyping technique and coating technologies applied to die components of a high pressure casting die for the production of aluminium components. Criteria for determining suitability were developed against which the technique was evaluated that included time, cost and life-expectancy. Results of accelerated testing procedures to evaluate the die material produced by the rapid prototyping technique and surface coatings and treatments of die materials for their resistance to washout, erosion, heat checking and corrosion in a high pressure die casting environment, are presented. The outcomes of this research will be used for further development and application of specific techniques, design principles and criteria for this approach.

Controlling the thermo-elastic behavior of tooling machines can only be achieved by systematic analysis, characterization and design of their fluidic system. In the first stage of this project, fundamental work was done to develop simulation methods for the calculation of the thermodynamic behavior of a representative example of a milling machine and each of its components. With experimental and numerical data it was proven, that significant improvement can be achieved by a proper design of heat transfer conditions of the fluidic system. To correct and counterbalance thermo-energetic effects, it will be necessary to develop new structures of the tooling machines systems which ensure the temperature-control of local subsystems in dependence of the actual working process. The work which is documented in this paper deals with the thermodynamic behavior of the motor spindle.

A necessidade deste trabalho se fez no setor de Planejamento de Fluxo de Materiais e Embalagens (PFME), que pertence ao departamento de engenharia de manufatura de uma filial de montadora instalada no Brasil. Neste setor existe a necessidade de se obter peças protótipo em um menor espaço de tempo possível para realização dos ensaios estáticos dos protótipos das embalagens especiais, uma vez que as embalagens precisam acondicionar as peças produzidas a partir da fase de preparação da produção em série do automóvel (pré-série ou PVS). Neste trabalho, a partir do estudo das tecnologias de Rapid Prototyping (RP) - Prototipagem Rápida (RP) e Rapid Tooling (RT) Ferramental Rápido (RT) é selecionada a técnica mais adequada para se atender às necessidades deste setor. Para isto, algumas condições de contorno foram consideradas: a aplicação das técnicas de RP e RT foram restringidas às peças externas do carro como portas, tampas dianteiras, traseiras e pára-lama e as fontes fornecedoras consultadas encontram-se no mercado doméstico. Com base em um estudo de caso pode-se validar esta proposta. Os resultados obtidos com a aplicação da técnica de ferramental rápido Vacuum Bagging foram uma redução média de 4,5 meses na obtenção das peças protótipo e uma redução global dos custos de aquisição de aproximadamente R$ 100.000,00. / The need of this work was made in the material flow planning and packing (PFME) section, that belongs to the manufacture engineering department of an assembler company installed in Brazil. In this sector, there is a growing need to obtain prototype parts in the shortest time possible in order to carry out static prototype tests of the special packing, since these racks need to be ready to assist the preparation phase of the series production of the vehicle (pre series or PVS). In this work, beginning from the study of Rapid Prototyping (RP) and Rapid Tooling (RT) technologies is selected the technique more adequate to assist to the needs of this section. For that purpose, some limiting conditions were considered: the application of the RP and RT techniques is limited to the external parts of the vehicle, such as doors, front and back hoods and fenders, and the consulted suppliers should be available in the domestic market. Based in a case study this proposal could be validated. The obtained results with the applied Rapid Tooling Vacuum Bagging technique were a medium reduction of 4,5 months in the prototype parts acquisition and a global reduction in the acquisition costs of approximately R$ 100.000,00.

Este trabalho avaliou a aplicação das tecnologias de prototipagem rápida por Impressão 3D e FDM (Fused Deposition Modeling) na produção de moldes rápidos. Esta avaliação foi feita com base nas qualidades das peças obtidas por vazamento nos moldes produzidos, bem como nas limitações encontradas em suas utilizações. Foram estabelecidas as principais diferenças do ponto de vista de qualidade, custos, tempos gastos e praticidade. Foram construídos moldes para peças que contemplando vários graus de dificuldades. Para cada ferramental foram obtidos lotes de peças, através dos quais foram analisadas e comparadas as qualidades dos protótipos. / This work evaluated the application of the Rapid Prototyping technologies 3D printer and FDM (Fused Deposition Modeling) in the rapid manufacturing of molds. This evaluation is based on the quality of the parts molded, as well as in the limitations found in the molds applications. As result the main differences related to quality, and usability was established. The molds produced parts with different degrees of geometric difficulties. For each mold, a few prototypes were produced and their qualities compared.

Finish machining of hardened steel is receiving increasing attention as an alternative to the grinding process, because it offers comparable part finish, lower production cost, shorter cycle time, fewer process steps, higher flexibility and the elimination of environmentally hazardous cutting fluids. In order to demonstrate its economic viability, it is of particular importance to enable critical hard turning processes to run in optimal conditions based on specified objectives and practical constraints. In this dissertation, a scientific and systematic methodology to design the optimal tool geometry and cutting conditions is developed. First, a systematic evolutionary algorithm is elaborated as its optimization block in the areas of: problem representation; selection scheme; genetic operators for integer, discrete and continuous design variables; constraint handling and population initialization. Secondly, models to predict process thermal, forces/stresses, tool wear and surface integrity are addressed. And then hard turning process planning and optimization are implemented and experimentally validated. Finally, an intelligent advisory system for hard turning technology by integrating experimental, numerical and analytical knowledge into one system with user friendly interface is presented. The work of this dissertation improves the state of the art in making tooling solution and process planning decisions for hard turning processes.

With the continuing trend towards miniaturization, micro milling plays an increasingly important role in fabrication of freeform and high-accuracy micro parts or components directly and cost-effectively. The technology is in kinematics scaled down from the conventional milling, however, existing knowledge and experiences are limited and comprehensive studies on the micro tooling performance are essential and much needed particularly for the process planning and optimization. The cutting performance of micro tools is largely dependent on the dynamic performance of machine tools, tooling characteristics, work material properties and process conditions, and the latter three aspects will be focused in the study. The state of the art of micro milling technology with respect to the tooling performance has been critically reviewed, together with modelling work for performance prediction as well as metrology and instrumentation for the performance characterization. A novel 3D finite element method taking into account the geometry of a micro tool, including the tool diameter, rake angle, relief angle, cutting edge radius and helix angle, has been proposed for modelling and simulation of the micro milling process. Validation through well-designed micro milling trials demonstrates that the approach is capable of characterizing the milling process effectively. With the support of FEM simulation developed, the tooling geometrical effects, including those from helix angle, rake angle and cutting edge radius with influences on cutting forces, tool stresses, tool temperatures, milling chip formation and temperatures have been comprehensively studied and compared for potential micro tool design and optimization purposes. In an effort to prolong the tool life and enhance the tooling efficiency, DLC and NCD coatings have been deposited on micro end mills by PE-CVD and HF-CVD processes respectively. Corresponding cutting performance of these coated tools have been assessed and compared with those of WC micro tools in both dry and wet cutting conditions so as for better understanding of the coating influence on micro tools. Furthermore, the cutting characteristics of the DLC coated and uncoated tools have been analysed through verified plane-strain simulations. The effects of coating friction coefficient, coating thickness and UCT have been determined and evaluated by design of simulation method. Mechanical, chemical and physical properties of a work material have a direct influence on its micro-machinability. Five most common engineering materials including Al 6061-T6, C101, AISI 1045, 304 and P20, have been experimentally investigated and their micro milling behaviours in terms of the cutting forces, tool wear, surface roughness, and micro-burr formation have been compared and characterized. Feed rate, cutting speed and axial depth of cut constitute the complete set of process variables and they have significant effects on the tooling performance. Fundamental understanding of their influences is essential for production engineers to determine optimum cutting parameters so as to achieve the maximum extension of the tool life. 3D FE-based simulations have been carried out to predict the process variable effects on the cutting forces, tool stresses, tool temperatures as well as micro milling chip formation and temperatures. Furthermore, experimental approach has been adopted for the surface roughness characterization. Suggestions on selecting practical cutting variables have been provided in light of the results obtained. Conclusions with respect to the holistic investigation on the tooling performance in micro milling have been drawn based on the research objectives achieved. Recommendations for future work have been pointed out particularly for further future research in the research area.