Intelligent Tool Management Strategies for Automated Manufacturing Systems
ABSTRACT
With the increase in automation and use of computer control in machine tools, the number of cutting tools per machining setup is on the increase. On one hand, such multi-tool setups offer the advantages of reduced down-time and cost of production and require less space and in-process inventory, and on the other hand, require proper tool management for economic operations. A number of strategies have been devised to solve the tool selection problems and a number of tool replacement policies have been proposed in the past. These strategies have been solved in isolation, whereas, a comprehensive algorithm for proper selection of tools out of those available in the tool magazine for performing operation and for replacement of tools on failure/wear is necessary. In this paper, taking cue from the computer memory management policies, four tool selection strategies have been presented and their performance in tandem with various tool replacement policies has been studied. The effect of important parameters such as reduction of tool life due to regrinding, limited number of regrindings, catastrophic failures etc. have been considered. Cost has been computed for each combination of tool selection and replacement policy. Also, the number of machine stoppages has been worked out in each case. The results indicate that the combination of various selection strategies with suitable replacement policies affects the overall cost.
With the increase in automation and use of computer control in machine tools, the number of cutting tools per machining setup is on the increase. On one hand, such multi-tool setups offer the advantages of reduced down-time and cost of production and require less space and in-process inventory, and on the other hand, require proper tool management for economic operations. A number of strategies have been devised to solve the tool selection problems and a number of tool replacement policies have been proposed in the past. These strategies have been solved in isolation, whereas, a comprehensive algorithm for proper selection of tools out of those available in the tool magazine for performing operation and for replacement of tools on failure/wear is necessary. In this paper, taking cue from the computer memory management policies, four tool selection strategies have been presented and their performance in tandem with various tool replacement policies has been studied. The effect of important parameters such as reduction of tool life due to regrinding, limited number of regrindings, catastrophic failures etc. have been considered. Cost has been computed for each combination of tool selection and replacement policy. Also, the number of machine stoppages has been worked out in each case. The results indicate that the combination of various selection strategies with suitable replacement policies affects the overall cost.
Cite this paper
nullD. Rao, C. Patvardhan and R. Singh, "Intelligent Tool Management Strategies for Automated Manufacturing Systems," Intelligent Control and Automation, Vol. 2 No. 4, 2011, pp. 405-412. doi: 10.4236/ica.2011.24046.
nullD. Rao, C. Patvardhan and R. Singh, "Intelligent Tool Management Strategies for Automated Manufacturing Systems," Intelligent Control and Automation, Vol. 2 No. 4, 2011, pp. 405-412. doi: 10.4236/ica.2011.24046.
References
[1] P. Tomek, “Tooling Strategies Related to FMS Management,” FMS Magazine, Vol. 5, 1986, pp. 102-107. [2] W. Eversheim, M. Lenhart and B. Katzy, “Information Modelling for Technology Oriented Tool Selection,” Annals of the CIRP, Vol. 43, No. 1, 1994, pp. 429-432. doi:10.1016/S0007-8506(07)62246-X [3] S. Pal, “An Expert System Approach for Scheduling and Tool management in an FMS Environment,” Unpublished M.Tech. Dissertation, I.I.T. Kanpur, Kanpur, 1991. [4] J. H. Zhang and S. Hinduja, “Determination of the Optimum Tool Set for a Given Batch of Turned Components,” Annals of the CIRP, Vol. 44, No. 1, 1995, pp. 445-450. doi:10.1016/S0007-8506(07)62360-9 [5] E. M. McCullough, “Economics of Multi-Tool Lathe Operations,” American Society of Mechanical Engineers, New York, 1963, pp. 402-404. [6] E. J. A. Armarego and R. H. Brown, “The Machining of Metals,” Prentice Hall, Inc., Englewood Cliffs, 1969. [7] N. I. Pa’sko, “Optimization of Multi-Tool Setups with Tool Life Scatter,” Russian Engineering Journal, Vol. 80, No. 9, 1970, pp. 82-85. [8] J. L. Batra and M. M. Barash, “Automated Computerized Optimization of Multi-Spindle Drilling with Probabilistic Tool Life,” Proceedings of 14th International Machine Tool Design and Research Conference, Manchester, 1973, pp. 125-136. [9] H. Bao, “Applications of Dynamic Programming to Optimize Tool Replacement Schedules for Multi-Tool Operations Involving Distributed Tool Lives,” ASME Journal of Mechanical Design, Vol. 102, 1980, pp. 446-451. doi:10.1115/1.3254767 [10] U. LaCommare, L. Diega, S. Nota and A. Passannante, “Optimum Tool Replacement Policies with Penalty Cost for Unforeseen Tool Failures,” International Journal of Production Research, Vol. 23, 1983, pp. 237-243. [11] J. Sharit, and S. Elhence, “Computerization of Tool Replacement Decision Making in Flexible Manufacturing Systems: A Human-System Perspective,” International Journal of Production Research, Vol. 27, No. 12, 1989, pp. 2027-2039. doi:10.1080/00207548908942672 [12] C. Zhou, J. Chandra and R. Wysk, “Optimal Cutting Tool Replacement Based on Tool Wear Status,” International Journal of Production Research, Vol. 28, No. 7, 1990, pp. 1357-1367. doi:10.1080/00207549008942798 [13] S. S. Tak, “Dynamic Tool Replacement Strategy and Its Characteristics,” Unpublished Ph.D. Dissertation, University of Jodhpur, Jodhpur, 1989. [14] S. Noro La Diega and A. Passannanti, “Optimum Tool Replacement Policies with Running-in of the Cutting Edge,” CIRP Annals—Manufacturing Technology, Vol. 33, No. 1, 1984, pp. 1-3. [15] G. D. Crite, R. I. Mills and J. J. Talavage, “PATHSIM, A Modular Simulator for an Automatic Tool Handling System Evaluation in FMS,” Journal of Manufacturing System, Vol. 4, No. 1, 1985, pp. 15-28. doi:10.1016/0278-6125(85)90004-4 [16] H. A. ElMaraghy, “Automated Tool Management in Flexible Manufacturing,” Journal of Manufacturing Systems, Vol. 4, No. 1, 1985, pp. 1-13. doi:10.1016/0278-6125(85)90003-2 [17] S. R. Hedin, P. R. Philipoom and M. K. Malhotra, “A Comparison of Static and Dynamic Tooling Policies in a General Manufacturing System,” IIE Transactions, Vol. 29, No. 1, 1997, pp. 69-80. doi:10.1080/07408179708966313 [18] A. Cederqvist, “Cutting Tool Development for Automation and FMS,” Proceedings of 4th International Conference on FMS, Stockholm, 15-17 October 1985, pp. 187-197. [19] F. Giusti, M. Santochi and G. Dini, “COATS: An Expert Module for Optimal Tool Selection,” CIRP Annals— Manufacturing Technology, Vol. 35, No. 1, 1986, pp. 337-340. [20] S. Chen, S. Hinduja and G. Barrow, “Automatic Selection of Tool for Roughing Operation,” International Journal of Machine Tool Manufacturing, Vol. 29, No. 4, 1989, pp. 535- 553. doi:10.1016/0890-6955(89)90070-9 [21] S. C. Syan, “Selecting Tools Like the Expert,” Journal of Integrated Manufacturing System, Vol. 1, No. 4, 1990, pp. 187-189. doi:10.1108/EUM0000000002072 [22] D. Domazet, “The Automatic Tool Selection with the Production Rules Matrix Method,” CIRP Annals—Manufacturing Technology, Vol. 39, No. 1, 1990, pp. 497-500. [23] P. G. Maropoulos and S. Hinduja, “Automatic Tool Selection for Rough Turning,” International Journal of Production Research, Vol. 29, No. 6, 1991, pp. 1185-1204. doi:10.1080/00207549108930127 [24] S. Hinduja and G. Barrow, “Sits—A Semi-Intelligent Tool Selection System for Turned Components,” CIRP Annals—Manufacturing Technology, Vol. 42, No. 1, 1993, pp. 535-539. [25] H.-B. Jun, Y.-D. Kim and H.-W. Suh, “Heuristics for a Tool Provisioning Problem in a Flexible Manufacturing System with an Automatic Tool Transporter,” Robotics and Automation, Vol. 15, No, 3, 1999, pp. 488-496. [26] M?zbayrak, R. B. R. De Souza and R. Bell, “Design of a Tool Management System for a Flexible Machining Facility,” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 215, No. 3, 2001, pp. 353-370. doi:10.1243/0954405011515424 [27] M. S. Akturk and S. Onen, “Dynamic Lot Sizing and Tool Management in Automated Manufacturing Sytems” Computers & Operations Research, Vol. 29, No. 8, 2002, pp. 1059-1079. doi:10.1016/S0305-0548(00)00103-9 [28] G. Svinjarevi?, A. Stoi? and J. Kopa?, “Implementation of Cutting Tool Management System,” Journal of Achievements in Materials and Manufacturing Engineering, Vol. 23, No. 1, 2007. [29] H. Arshad, R. Hassan, N. Omar and S. Sahran, “Virtual Cutting Tool Management System for Milling Process” International Journal of Computer Science and Networks, Vol. 10 No. 2, 2010.
[1] P. Tomek, “Tooling Strategies Related to FMS Management,” FMS Magazine, Vol. 5, 1986, pp. 102-107. [2] W. Eversheim, M. Lenhart and B. Katzy, “Information Modelling for Technology Oriented Tool Selection,” Annals of the CIRP, Vol. 43, No. 1, 1994, pp. 429-432. doi:10.1016/S0007-8506(07)62246-X [3] S. Pal, “An Expert System Approach for Scheduling and Tool management in an FMS Environment,” Unpublished M.Tech. Dissertation, I.I.T. Kanpur, Kanpur, 1991. [4] J. H. Zhang and S. Hinduja, “Determination of the Optimum Tool Set for a Given Batch of Turned Components,” Annals of the CIRP, Vol. 44, No. 1, 1995, pp. 445-450. doi:10.1016/S0007-8506(07)62360-9 [5] E. M. McCullough, “Economics of Multi-Tool Lathe Operations,” American Society of Mechanical Engineers, New York, 1963, pp. 402-404. [6] E. J. A. Armarego and R. H. Brown, “The Machining of Metals,” Prentice Hall, Inc., Englewood Cliffs, 1969. [7] N. I. Pa’sko, “Optimization of Multi-Tool Setups with Tool Life Scatter,” Russian Engineering Journal, Vol. 80, No. 9, 1970, pp. 82-85. [8] J. L. Batra and M. M. Barash, “Automated Computerized Optimization of Multi-Spindle Drilling with Probabilistic Tool Life,” Proceedings of 14th International Machine Tool Design and Research Conference, Manchester, 1973, pp. 125-136. [9] H. Bao, “Applications of Dynamic Programming to Optimize Tool Replacement Schedules for Multi-Tool Operations Involving Distributed Tool Lives,” ASME Journal of Mechanical Design, Vol. 102, 1980, pp. 446-451. doi:10.1115/1.3254767 [10] U. LaCommare, L. Diega, S. Nota and A. Passannante, “Optimum Tool Replacement Policies with Penalty Cost for Unforeseen Tool Failures,” International Journal of Production Research, Vol. 23, 1983, pp. 237-243. [11] J. Sharit, and S. Elhence, “Computerization of Tool Replacement Decision Making in Flexible Manufacturing Systems: A Human-System Perspective,” International Journal of Production Research, Vol. 27, No. 12, 1989, pp. 2027-2039. doi:10.1080/00207548908942672 [12] C. Zhou, J. Chandra and R. Wysk, “Optimal Cutting Tool Replacement Based on Tool Wear Status,” International Journal of Production Research, Vol. 28, No. 7, 1990, pp. 1357-1367. doi:10.1080/00207549008942798 [13] S. S. Tak, “Dynamic Tool Replacement Strategy and Its Characteristics,” Unpublished Ph.D. Dissertation, University of Jodhpur, Jodhpur, 1989. [14] S. Noro La Diega and A. Passannanti, “Optimum Tool Replacement Policies with Running-in of the Cutting Edge,” CIRP Annals—Manufacturing Technology, Vol. 33, No. 1, 1984, pp. 1-3. [15] G. D. Crite, R. I. Mills and J. J. Talavage, “PATHSIM, A Modular Simulator for an Automatic Tool Handling System Evaluation in FMS,” Journal of Manufacturing System, Vol. 4, No. 1, 1985, pp. 15-28. doi:10.1016/0278-6125(85)90004-4 [16] H. A. ElMaraghy, “Automated Tool Management in Flexible Manufacturing,” Journal of Manufacturing Systems, Vol. 4, No. 1, 1985, pp. 1-13. doi:10.1016/0278-6125(85)90003-2 [17] S. R. Hedin, P. R. Philipoom and M. K. Malhotra, “A Comparison of Static and Dynamic Tooling Policies in a General Manufacturing System,” IIE Transactions, Vol. 29, No. 1, 1997, pp. 69-80. doi:10.1080/07408179708966313 [18] A. Cederqvist, “Cutting Tool Development for Automation and FMS,” Proceedings of 4th International Conference on FMS, Stockholm, 15-17 October 1985, pp. 187-197. [19] F. Giusti, M. Santochi and G. Dini, “COATS: An Expert Module for Optimal Tool Selection,” CIRP Annals— Manufacturing Technology, Vol. 35, No. 1, 1986, pp. 337-340. [20] S. Chen, S. Hinduja and G. Barrow, “Automatic Selection of Tool for Roughing Operation,” International Journal of Machine Tool Manufacturing, Vol. 29, No. 4, 1989, pp. 535- 553. doi:10.1016/0890-6955(89)90070-9 [21] S. C. Syan, “Selecting Tools Like the Expert,” Journal of Integrated Manufacturing System, Vol. 1, No. 4, 1990, pp. 187-189. doi:10.1108/EUM0000000002072 [22] D. Domazet, “The Automatic Tool Selection with the Production Rules Matrix Method,” CIRP Annals—Manufacturing Technology, Vol. 39, No. 1, 1990, pp. 497-500. [23] P. G. Maropoulos and S. Hinduja, “Automatic Tool Selection for Rough Turning,” International Journal of Production Research, Vol. 29, No. 6, 1991, pp. 1185-1204. doi:10.1080/00207549108930127 [24] S. Hinduja and G. Barrow, “Sits—A Semi-Intelligent Tool Selection System for Turned Components,” CIRP Annals—Manufacturing Technology, Vol. 42, No. 1, 1993, pp. 535-539. [25] H.-B. Jun, Y.-D. Kim and H.-W. Suh, “Heuristics for a Tool Provisioning Problem in a Flexible Manufacturing System with an Automatic Tool Transporter,” Robotics and Automation, Vol. 15, No, 3, 1999, pp. 488-496. [26] M?zbayrak, R. B. R. De Souza and R. Bell, “Design of a Tool Management System for a Flexible Machining Facility,” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 215, No. 3, 2001, pp. 353-370. doi:10.1243/0954405011515424 [27] M. S. Akturk and S. Onen, “Dynamic Lot Sizing and Tool Management in Automated Manufacturing Sytems” Computers & Operations Research, Vol. 29, No. 8, 2002, pp. 1059-1079. doi:10.1016/S0305-0548(00)00103-9 [28] G. Svinjarevi?, A. Stoi? and J. Kopa?, “Implementation of Cutting Tool Management System,” Journal of Achievements in Materials and Manufacturing Engineering, Vol. 23, No. 1, 2007. [29] H. Arshad, R. Hassan, N. Omar and S. Sahran, “Virtual Cutting Tool Management System for Milling Process” International Journal of Computer Science and Networks, Vol. 10 No. 2, 2010.