Optimization Methods Wr- Computer Hided and Integrated Manufacturing Systems H 5-Volume Set Cornelius T Leondes Vol.3 Optimization Methods Computer Aided and Integrated Manufacturing Systems A 5-Volume Set This page is intentionally left blank Vol.3 Optimization Methods Computer Aided and Integrated Manufacturing Systems A 5-Volume Set Cornelius T Leondes Un'mrsitf of California, Los Angeles, USA II&5 World Scientific mil New Jersey • London • Singapore • Hong Kong Published by World Scientific Publishing Co. Pte. Ltd. 5 Toh Tuck Link, Singapore 596224 USA office: Suite 202, 1060 Main Street, River Edge, NJ 07661 UK office: 57 Shelton Street, Covent Garden, London WC2H 9HE British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. COMPUTER AIDED AND INTEGRATED MANUFACTURING SYSTEMS A 5-Volume Set Volume 3: Optimization Methods Copyright © 2003 by World Scientific Publishing Co. Pte. Ltd. All rights reserved. This book, or parts thereof, may not be reproduced in any form or by any means, electronic or mechanical, including photocopying, recording or any information storage and retrieval system now known or to be invented, without written permission from the Publisher. For photocopying of material in this volume, please pay a copying fee through the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, USA. In this case permission to photocopy is not required from the publisher. ISBN 981-238-339-5 (Set) ISBN 981-238-981-4 (Vol. 3) Desk Editor: Tjan Kwang Wei Typeset by Stallion Press Printed by Fulsland Offset Printing (S) Pte Ltd, Singapore Preface Computer Technology This 5 volume MRW (Major Reference Work) is entitled "Computer Aided and Integrated Manufacturing Systems". A brief summary description of each of the 5 volumes will be noted in their respective PREFACES. An MRW is normally on a broad subject of major importance on the international scene. Because of the breadth of a major subject area, an MRW will normally consist of an integrated set of distinctly titled and well-integrated volumes each of which occupies a major role in the broad subject of the MRW. MRWs are normally required when a given major subject cannot be adequately treated in a single volume or, for that matter, by a single author or coauthors. Normally, the individual chapter authors for the respective volumes of an MRW will be among the leading contributors on the international scene in the subject area of their chapter. The great breadth and significance of the subject of this MRW evidently calls for treatment by means of an MRW. As will be noted later in this preface, the technology and techniques utilized in the methods of computer aided and integrated manufacturing systems have pro duced and will, no doubt, continue to produce significant annual improvement in productivity — the goods and services produced from each hour of work. In addi tion, as will be noted later in this preface, the positive economic implications of constant annual improvements in productivity have very positive implications for national economies as, in fact, might be expected. Before getting into these matters, it is perhaps interesting to briefly touch on Moore's Law for integrated circuits because, while Moore's Law is in an entirely dif ferent area, some significant and somewhat interesting parallels can be seen. In 1965, Gordon Moore, cofounder of INTEL made the observation that the number of tran sistors per square inch on integrated circuits could be expected to double every year for the foreseeable future. In subsequent years, the pace slowed down a bit, but den sity has doubled approximately every 18 months, and this is the current definition of Moore's Law. Currently, experts, including Moore himself, expect Moore's Law to hold for at least another decade and a half. This is impressive with many sig nificant implications in technology and economies on the international scene. With these observations in mind, we now turn our attention to the greatly significant and broad subject area of this MRW. VI Preface "The Magic Elixir of Productivity" is the title of a significant editorial which appeared in the Wall Street Journal. While the focus in this editorial was on produc tivity trends in the United States and the significant positive implications for the economy in the United States, the issues addressed apply, in general, to developed economies on the international scene. Economists split productivity growth into two components: Capital Deepen ing which refers to expenditures in capital equipment, particularly IT (Informa tion Technology) equipment: and what is called Multifactor Productivity Growth, in which existing resources of capital and labor are utilized more effectively. It is observed by economists that Multifactor Productivity Growth is a better gauge of true productivity. In fact, computer aided and integrated manufacturing systems are, in essence, Multifactor Productivity Growth in the hugely important manufac turing sector of global economies. Finally, in the United States, although there are various estimates by economists on what the annual growth in productivity might be, Chairman of the Federal Reserve Board, Alan Greenspan — the one economist whose opinions actually count, remains an optimist that actual annual productivity gains can be expected to be close to 3% for the next 5 to 10 years. Further, the Treasure Secretary in the President's Cabinet is of the view that the potential for productivity gains in the US economy is higher than we realize. He observes that the penetration of good ideas suggests that we are still at the 20 to 30% level of what is possible. The economic implications of significant annual growth in productivity are huge. A half-percentage point rise in annual productivity adds $1.2 trillion to the federal budget revenues over a period of ten years. This means, of course, that an annual growth rate of 2.5 to 3% in productivity over 10 years would generate anywhere from $6 to $7 trillion in federal budget revenues over that time period and, of course, that is hugely significant. Further, the faster productivity rises, the faster wages climb. That is obviously good for workers, but it also means more taxes flowing into social security. This, of course, strengthens the social security program. Further, the annual productivity growth rate is a significant factor in controlling the growth rate of inflation. This continuing annual growth in productivity can be compared with Moore's Law, both with huge implications for the economy. The respective volumes of this MRW "Computer Aided and Integrated Manu facturing Systems" are entitled: Volume 1: Computer Techniques Volume 2: Intelligent Systems Technology Volume 3: Optimization Methods Volume 4: Computer Aided Design/Computer Aided Manufacturing (CAD/CAM) Volume 5: Manufacturing Process A description of the contents of each of the volumes is included in the PREFACE for that respective volume. Preface vn Optimization methods will become an increasingly important factor in manufac turing systems as they have proven to enhance productivity. The design of cellular manufacturing systems will also be optimized, again with significant implications for productivity. Computer Aided Design (CAD) methods for manufacturing processes, such as the ubliquitous injection molding process, will increasingly utilize optimiza tion methods. Rapid prototyping has become a way of life in manufacturing sys tems and this will benefit greatly from the optimization methods. The CAD/CAM (Computer Aided Design/Computer Aided Manufacturing) process will necessar ily require visual assessment techniques of free-form surfaces in order to assure an optimal product. These and numerous other significant topics are treated rather comprehensively in Volume 3. As noted earlier, this MRW (Major Reference Work) on "Computer Aided and Integrated Manufacturing Systems" consists of 5 distinctly titled and well integrated volumes. It is appropriate to mention that each of the volumes can be utilized individually. The great significance and the potential pervasiveness of the very broad subject of this MRW certainly suggests the clear requirement of an MRW for an adequately comprehensive treatment. All of the contributors to this MRW are to be highly commended for their splendid contributions that will provide a significant and unique reference source for students, research workers, practitioners, computer scientists and others, as well as institutional libraries on the international scene for years to come. This page is intentionally left blank Contents Preface v Chapter 1 Optimal Dynamic Facility Design of Manufacturing Systems 1 Timothy L. Urban Chapter 2 Computer Techniques and Applications for the Design of Optimum Cellular Manufacturing Systems 25 Mingyuan Chen Chapter 3 Optimal Computer Aided Design (CAD) Methods and Applications for Injection Molding Processes in Manufacturing Systems 67 Seong Jin Park and Tai Hun Kwon Chapter 4 Computer Control Systems Techniques and Applications in Manufacturing Systems 139 Zahra Idelmerfaa and Jacques Richard Chapter 5 Rapid Prototyping Technologies and Limitations 165 Ghee Kai Chua and Siau Meng Chou Chapter 6 Visual Assessment of Free-Form Surfaces in CADCAM 187 Robert J. Cripps and Alan A. Ball Index 219