Professor of School of Engineering, Design and Built Environment, Western Sydney University, Australia. His research interests cover Industry 4.0, Additive Manufacturing, Advanced Engineering Materials and Structures (Metals and Composites), Multi-scale Modelling of Materials and Structures, Metal Forming and Metal Surface Treatment.
Abstract—When punching cable ducts made of polycarbonate/acrylonitrile-butadiene-styrene (PC/ABS), burr and film often occur. These make additional deburring processes necessary, which are reflected in the product price. In the following study, the punching process is examined by means of Design of Experiments in order to highlight the relationship between the input variables (factors) and the output variables (quality characteristics). The punching process was analyzed and the key factors were identified and subsequently rated by means of a Failure Mode and Effects Analysis (FMEA). The rated factors were then selected using the Pareto principle. Factor levels and a D-optimal screening test plan were defined with the Software Modde. The resulting quality characteristics were categorically evaluated using illustrated evaluation catalogs. The mathematical models of the quality characteristics were then optimized and evaluated. The results indicate that the clearance is the decisive variable for all five quality characteristics considered. It is interesting to note that for some quality characteristics a reduction of the clearance would be positive, whereas for some a reduction would be positive. It is assumed that an ideal clearance size exists in between these limits.
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