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001 17页,A Review of Research in Mechanical Engineering Design. Part II Representations, Analysis, and Design for the Life Cycle PDF
001 17页,A Review of Research in Mechanical Engineering Design. Part II Representations, Analysis, and Design for the Life Cycle PDF
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Abstract. This is the second of a two-part paper summarizing and reviewing research in mechanical engineering
design theory and methodology. Part I included 1) descriptive models; 2) prescriptive models; and 3) computer-based models of design processes. Part II includes:
4) languages, representations, and environments for design; 5) analysis in support of design; and 6) design for
manufacture and the life cycle. For each area, we discuss
the current topics of research and the state of the art,
emphasizing recent significant advances. A final section
is included that summarizes the six major areas and lists
open research issues.
Introduction
This two-part paper, the first in a series of reviews
to be published in Research in Engineering Design,
summarizes and reviews the state of research in
engineering design theory and methodology, concentrating on mechanical engineering design. Subsequent reviews will concentrate on other areas of
engineering design or on special sub-topics. The
goal of the series is to inform the community at
large of advances in the developments in engineering design research. We also hope that it will enable
researchers to place their work in context and thus
guide continuing work. The series of papers is also
intended to be an efficient starting place for those
who wish to become familiar with the engineering
design literature relevant to their interests.
There are, of necessity, limits to the nature and
scope of this review. First, the review is not intended to be a substitute for reading complete papers; it is intended only as a brief summary of, and
guide to, the literature. Although we have made
every reasonable effort to be complete, omissions
are inevitable. There can also be errors of commission caused by misinterpretation or lack of full understanding on our part of papers included in the
* Reprint requests: Robotics Institute, Carnegie Mellon University, Pittsburgh, PA 15213, USA
These six categories are certainly not mutually exclusive, and some research overlaps two or more
areas. In such cases, we have done our best to inform readers where research projects have been
placed. In Part I, the first three of the above six
topics were reviewed. In Part II, we review the last
122
5.1
Representation of Form
The representation of the geometric form of a mechanical design has received much attention,
largely through the emergence of computer-aided
design systems. We discuss two different, but converging approaches to the representation of form.
The first approach is geometric modeling, either
boundary representation (b-rep) or constructive
solid geometry (CSG) in which the objective is to
create a valid, computer-based representation of a
solid object. The other approach is shape grammars, and their extensions, in which the goal is to
create geometric rules (a grammar) by which a class
of objects can be generated or described.
research, because the same need--that of increasing the expressiveness of the representation-drives much of the research in design representation. Voelcker [145] also discusses the limitations of
the current geometric models as design systems because their purpose is to represent the geometry of
a completed geometric object, rather than an evolving one. A discussion along similar lines can be
found in Nielsen [94].
One approach to creating geometric modeling
systems for design is to use variational geometry.
Gossard [50, 77, 81] combines CSG and boundary
models in an object graph so that changes in dimensions result in changes in geometry and topology.
Variational geometry is most useful for redesign
and tolerance analysis and synthesis.
Recently, non-manifold geometric modeling systems have been created by Weiler [146, 147] and by
Prinz et al. [56]. These non-manifold systems are
promising as the underlying geometric modellers for
design systems because one-dimensional, two-dimensional, and three-dimensional geometric entities can be represented in a uniform fashion. In addition, these models contain topological information
that enables high-level descriptions of features.
(See Section 5.3.)
5.1.2 Shape grammars. In 1975, Stiny [126] created shape grammars based on the formalisms of
computational linguistics [28]. Using a formal grammar, instances of a class of objects can be generated
based on a sequence of production rules. Architects
in particular have been interested in shape grammars, using them to generate a family of floor plans
or ornamentation. For example, Flemming [48] has
used a variant of shape grammars to generate facades and floor plans for new buildings so they
would blend into a historic district. Tutorials on
shape grammars can be found in both Earl [40] and
Stiny [127]. The textbook, An Introduction to Formal Language Theory [89], which unites formal
language theory with an introduction to computational linguistics, is a good starting point for design
researchers interested in formal languages.
Researchers from several different areas have
become interested in using the formalism of grammars to describe, generate, and parse designs. For
example, Woodbury [156] has created a structure
grammar that extends shape grammars to structures
in space, and he is now working on a three-dimensional grammar for solids [60]. Stiny [129] has written about possible extensions to his work that
would use grammars to generate design attributes
other than simply shape.
Fitzhorn [47] shows the formal relationships between language theory and solid modeling systems.
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124
Product Models
125
Environments
126
5.6
Summary
6.1
implemented a design and analysis tool for mechanical components and assemblies called OPTDEX
(Optimal Design Expert). Design cells are created
that support the design of various elements such as
bearings or speed reducers. The concept in this research is to provide an environment that integrates
AI, mechanical design knowledge, and optimization
methods.
Another interface for mechanical designers to
optimization is described by Ishii and Barkan [67].
They propose a rule-based sensitivity analysis
methodology that uses a table of production rule
relationships between design variables and performance parameters. The approach provides interactive advice about critical constraints during the
parametric iterative redesign process and about formulating problems for optimization.
Other work that provides assistance to designers
using optimization methods is found in Balachandran and Gero [12]. In this work, knowledge-based
systems are described to assist formulation and selection of optimization algorithms. Diaz [36] describes and illustrates an approach based on fuzzy
set theory that enables a richer, more flexible definition of the criterion function than traditional optimization methods. Additional references that provide
designer interfaces to optimization include [22, 85,
103, 115]. Haftka [58] gives a review of structural
shape optimization methods. Some possible dangers of structural optimization techniques are discussed by Thompson [137]. A good review of optimization methods for large-scale systems can be
found in [8].
Finally, methods for using optimization methods
in the presence of the complex concerns of design
such as cost and delivery time are discussed by Nakazawa [92] and by Mackenzie [84]. Nakazawa's
work is interesting because he uses as his objective
function the minimization of information required in
manufacturing [132].
127
128
6.4 Summary
Once a design has been carried to the detailed design stage, analysis procedures are available to predict or simulate the performance of the design along
many different dimensions. Better interfaces to
these procedures are necessary to make them more
accessible to designers and to enable them to be
used properly. However, a much greater need exists for better analytical tools in the early stages of
design when critical decisions are made based on
qualitative information. Tools and methods are
needed to enable designers to explore alternatives
fully and efficiently. Designs must be evaluated and
analyzed at every stage from conceptual to detailed
design. At the moment, little is known about how to
do this, although the work noted above is an encouraging beginning.
7.1
Concurrent Design
129
The systems described above require that the designers compute and enter manually the required
data on size, symmetry, and other features. Myers
[91] describes an algorithm which, when an assembly is designed in a geometric solid modeller, automatically computes the manual handling times of
the various components using Boothroyd's theory
and data. In this work, the features needed are extracted from the solid modeller boundary representations. This automation of manual handling analysis related to design has not yet been extended to
automatic handling or to insertion times.
In other design for manufacturing work, Poll
[74, 104] has compiled and organized knowledge
on design for forging. As with Boothroyd's work in
assembly, analyses of forging relative cost and difficulty are based on identification of selected design
features, and the results point to potential design
problems or improvements from the viewpoint of
the forging process. Work by these researchers is in
progress on design for injection molding [108].
Heuristic information is available from firms and
industry associations related to design for manufacturability. For example, for casting there is [21], for
extrusion [3], tbr forging [104], and for injection
molding [108]. However, this type of knowledge is
not yet embedded in CAD and solid modeling systems in a way that makes it available to designers
using these systems.
In work that is similar in spirit to Suh's axiomatic
approach to design, Ayers [I0] discusses manufacturing as the concentration of information in matter.
While he does not discuss design per se, Ayers sees
the optimal design and manufacturing process as
the one that maximizes the economic value by minimizing the information required to describe and
produce a product. An overview in design for manufacture is given by Stoll in [130].
7.3 Tolerances
Although tolerances are critical to both functional
performance and manufacturing cost, tolerances
have received very little theoretical treatment.
There are three areas for research: 1) the relationships between tolerances and cost, 2) the relationships between tolerances and functional performance, and 3) the representation of tolerances in
computer-based design systems.
Published data on the relationships between tolerances and costs are almost non-existent. Chase
[24] has fit cost-tolerance curves to data published
by Jamieson [68]. Work is in progress to analyze
and publish more data that can perhaps provide the
130
unreliable designs. Koen et al. [97] have investigated techniques such as fault tree analysis to develop tools to aid designers in designing large complex systems.
7.5
CAD Advisors
7.6 Summary
To date, design-for-X has meant primarily design
for manufacturing. Research in design for manufacturing is extensive, especially for assembly and machining. Research effort in knowledge acquisition
and organization is still needed, as well as in practical ways to get the information to designers in a
useful and timely fashion. In contrast, a fundamental understanding of tolerances is still lacking, al-
8 Summary
A research review should not only point to what has
been done, but also to what remains undone. We
summarize here by listing the accomplishments and
the outstanding research issues, as we see them,
organized by the six topic areas of Parts I and II in
the review.
Descriptive M o d e l s
State o f the Art
131
132
1. A major research issue is the analysis and evaluation of designs at the early and intermediate
stages of design. Research is needed on the
generation and evaluation of alternatively concepts, embodiments, and configurations to
complement the observed tendency of designers to pursue a single-concept design.
2. Another open research question is how to provide designers with the ability to design and
analyze, not only at different levels of abstraction, but also from various functional viewpoints, for example from a kinematic, structural, or thermal viewpoint.
3. Research is needed to create CAD systems
that support conceptual design stages by enabling designers to design, modify, and analyze
at multiple levels of abstraction and in multiple
viewpoints.
4. More work is required to complete and disseminate automated interfaces for parametric design and optimization as well as for detail design and finite element analyses.
Design for Manufacturing and the Life-Cycle
State o f the Art
2.
3.
4.
5.
6.
and then to recompose and assemble the resuiting designs into a product.
The organization and communication protocols necessary for concurrent design are not
understood.
Continued acquisition and organization of
manufacturing knowledge in forms useful to
designers is needed.
Fundamental and applied work on tolerances,
especially relating cost to performance, is essential.
More design-for-X studies are needed if concurrent design for life-cycle performance is to
become a reality.
CAD advisory system must be able to deal with
more complex geometry and with combinations of features.
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