Drawbacks of the conventional manufacturing systems
In conventional manufacturing, there is lots of time and money wasted on building the physical prototypes of the manufacturing processes to be used before the actual production starts. This takes a lot of time which can be used to optimize the product design and market the product in a better way. There is also lots of money and material wastage if more physical prototypes are required. With increasing competition in today’s world, the conventional way of setting up production processes causes the company a fortune. It was time for an innovation and this is how Virtual Manufacturing was born.
What is Virtual Reality?
Virtual Reality (VR) is an exciting new technology for which the most important benefits are the ability to do human-in-the-loop, real time, “what if” scenarios, reducing development time and reducing time to deliver products to the market. Virtual reality promises a ready ability to interact in three dimensional space. In particular it is possible to provide a visual simulation of familiar real-world environments, and to make changes within such an environment.
Perhaps one of the most interesting and important of these recent developments is called “Virtual Manufacturing”. Often termed “The Next Revolution in Global Manufacturing”, virtual manufacturing involves the simulation of a product and the processes involved in fabrication. Virtual Manufacturing (VM) is defined to be an integrated, synthetic manufacturing environment exercised to enhance all levels of decision and control. In simple words, the vision of Virtual Manufacturing is to provide a capability to “Manufacture in the Computer”. Virtual Manufacturing (VM) is defined to be an integrated, synthetic manufacturing environment exercised to enhance all levels of decision and control.
In essence, VM will ultimately provide a modeling and simulation environment so powerful that the fabrication/assembly of any product, including the associated manufacturing processes, can be simulated in the computer. This powerful capability would take into account all of the variables in the production environment from shop floor processes to enterprise transactions. In other words, VM will accommodate the visualization of interacting production processes, process planning, scheduling, assembly planning, logistics from the line to the enterprise, and related impacting processes such as accounting, purchasing and management. In addition, VM also reduces the cost of tooling, eliminates the need for multiple physical prototypes, and reduces material waste. This allows everyone to “get it right the first time”.
VM utilizes nonlinear finite element analysis technologies to provide detailed information about a product, which is than used for optimization of factors such as manufacturability, final shape, residual stress and life-cycle estimations. At the core of VM lies nonlinear FEA technology.
In Virtual Manufacturing Process Of Manufacturing include following steps:
1. Preliminary Design Of Products.
2. Preparing product models ,assembly using 3d design Software like Solidworks, CATIA, Creo
3.Engineering And functional analysis
4. Manufacturing analysis
5. Verification of design Parameters
6. Acceptable Design.
FEWER PROTOTYPES –
The more trials you can simulate in a virtual environment, the less physical prototypes you need to perfect your design. This means you spend more time up front in engineering and design, and less resources running physical trials. Virtual prototyping is cheaper than building physical models and optimizing your design by trial-and-error. It is not complete replacement for physical testing, but it can minimize the effort and enable the resulting physical tests to be more successful.
LESS MATERIAL WASTE –
If you build fewer physical models, you waste less material in the form of prototypes as well as the tooling used to create them.
REDUCED COST OF TOOLING –
Again it follows that if you build fewer prototypes, then you develop fewer tools, which are typically very expensive. Furthermore, by modeling the tools, you can reduce tool wear, thus increasing tool life.
CONFIDENCE IN MANUFACTURING PROCESS –
Even if the tools are properly designed, the control of the tools may affect the quality of the part produced. VM allows you to simulate the part, the tools, and their control. This simulation can let you optimize your tool control before building prototypes, again letting you “get it right the first time”.
IMPROVED QUALITY –
It improves their part quality by utilizing VM techniques.
There are numerous examples throughout this paper, and almost all of them result in a part with quality produced at lower cost than previously attained through traditional prototyping techniques.
REDUCED TIME TO MARKET –
Time to market is becoming increasingly critical in an age where information can be transmitted and shared readily.