KNOWLEDGE BASED DESIGN FOR COMPOSITE BOND TOOLS

The recent development of knowledge based design systems promises to revolutionize the tool design methods currently employed throughout industry. This revolution, while promising to greatly reduce labor cost and cycle time, will not be painless. Problems encountered while implementing these systems includes the selection of a viable project, the development of the rule base, and dealing with the complexity associated with programming generic geometric modeling applications. While developing these systems, it’s important to recognize that the knowledge based system is only a part of a total solution, and that it must be integrated with existing systems such as CAD/CAM. The project chosen at Bell consists of a system to design and manufacture composite bond tools. The tool surface geometry is created on the CAD system. It is then downloaded to the knowledge based system, where the tool is automatically designed. The design produces a three-dimensional (3-D) model of the tool, a two-dimensional (2-D) detail drawing of each component, and an exploded drawing of the tool assembly. This graphical data is then uploaded to the CAD system, where the tool design drawing is completed and the numerical control (NC) data is automatically created to cut out the substructure components, using a waterjet. The system works because a balance is struck between what is programmed and what is done manually. The organization must be adapted to make use of this technology. Experts must be found to gather the rule base and to program the knowledge based system. Commitment to this technology is required because it requires significant capital outlays and a change in job descriptions. It also requires adequate lead time to implement an application. The benefits include greatly reduced labor costs, reduced cycle time, and a reduction in traditional CAD/CAM capital costs. Knowledge based systems do not provide a 100% solution to all design problems, but with thoughtful application they can have a positive impact on a company’s bottom line.