A theoretical simulation study was performed to study how surface roughness of the workpiece and datum can affect the locating precision of multiple station manufacturing processes using a mechanical alignment system. Our analysis shows that geometric consideration, a factor that has not been treated before, is extremely important for many multi-station applications. As expected, the level of alignment precision decreases when the level of surface roughness of the workpieces increases. Our analysis also shows that the effect of the sample roughness on the level of alignment precision depends heavily on the difference in the relative positions of the datum between different workstations.

Issue Section:
Technical Papers
Keywords:
liquid crystal displays, manufacturing processes, workstations, rough surfaces
Topics:
Manufacturing, Simulation, Surface roughness, Deformation
1.
Jorgensen, Finn, 1998, The Complete Handbook of Magnetic Recording, Chapter 9, Tab Books.
2.
Lee, N. K. S., Jain, A., and Keppeler, E., “Apparatus and Method for Fabrication A Lens/Mirror Tower,” US Patent 5,260,928.
3.
O’Mara, William C., 1993, Liquid Crystal Flat Panel Displays Manufacturing Science & Technology, Van Nostrand Reinhold, New York.
4.
Asada
,
H.
, and
By
,
A. B.
,
1985
, “
Kinematic Analysis of Workpart Fixturing for Flexible Assembly with Automatically Reconfiguration Fixtures
,”
IEEE J. Rob. Autom.
,
RA-1
, No.
2
, pp.
86
–
94
.
5.
Bazrov
,
B. M.
, and
Sorokin
,
A. I.
,
1982
, “
The Effect of Clamping Sequence on Workpiece Mounting Accuracy
,”
Sov. Eng. Res.
,
2
, No.
10
, pp.
92
–
95
.
6.
Batyrov
,
U. D.
,
1984
, “
Factors Affecting Setting Errors of Pallet Fixtures
,”
Sov. Eng. Res.
,
4
, No.
4
, pp.
67
–
69
.
7.
Batyrov
,
U. D.
,
1986
, “
More Accurate Clamping of Pallet Fixtures
,”
Sov. Eng. Res.
,
6
, No.
9
, pp.
58
–
60
.
8.
Cogun
,
C.
,
1992
, “
The Importance of the Application Sequence of Clamping Forces on Workpiece Accuracy
,”
J. Eng. Ind.
,
114
, pp.
539
–
543
.
9.
Weill, R., Darel, I., and Laloum, M., 1991, “
The Influence of Fixture Positioning Errors on the Geometric Accuracy of Mechanical Parts,” Proceedings of CIRP Conference on PE&MS, pp. 215–225.
10.
Wu
,
N. H.
,
Chan
,
K. C.
, and
Leong
,
S. S.
,
1997
, “
Static Interactions of Surface Contacts in a Fixture-Workpiece System
,”
Int. J. Comput. Appl. Technol.
,
10
, Nos.
3/4
, pp.
133
–
151
.
11.
Hockenberger
,
M. J.
, and
DeMeter
,
E. C.
,
1996
, “
the Application of Meta Functions to the Quasi-Static Analysis of Workpiece Displacement Within a Machining Fixture
,”
ASME J. Manuf. Sci. Eng.
,
118
, pp.
325
–
331
.
12.
Shawki
,
G. S. A.
, and
Abdel-Aal
,
1996a
, “
Rigidity Consideration in Fixture Design-Contact Rigidity at Locating Elements
,”
Int. J. Mach. Tool Des. Res.
,
6
, pp.
31
–
43
.
13.
Shawki
,
G. S. A.
, and
Abdel-Aal
,
1996b
, “
Rigidity Consideration in Fixture Design-Contact Rigidity at Clamping Elements
,”
Int. J. Mach. Tool Des. Res.
,
6
, pp.
207
–
220
.
14.
Hockenberger
,
M. J.
, and
DeMeter
,
E. C.
,
1995
, “
The Effect of Machining Fixture Design Parameters on Workpiece Displacement
,”
ASME J. Manufact. Rev.
,
8
, No.
1
, pp.
22
–
32
.
15.
Shawki
,
G. S. A.
, and
Abdel-Aal
,
1965
, “
Effect of Fixture Rigidity and Wear on Dimensional Accuracy
,”
Int. J. Mach. Tool Des. Res.
,
5
, pp.
183
–
202
.
16.
Lee
,
N. K. S.
, and
Joneja
,
A.
,
1997
, “
A Methodology to Improve Manufacturing Precision in the Presence of Workpiece Imperfections
,”
ASME J. Manuf. Sci. Eng.
,
119
, pp.
616
–
622
.
17.
Lee, N. K. S., Hon, K. K. C., Cheung, V. P. Y., and Joneja, A, 1998, “Effect of Datum Securing Method on Precision of Mechanical Alignment System,” submitted to ASME Journal of Manufacturing Science and Engineering.
18.
Lee
,
N. K. S.
,
Cai
,
Y. M.
, and
Joneja
,
A.
,
1997
, “
A High Resolution Multi-dimensional Displacement Monitoring System
,”
Opt. Eng.
,
36
, No.
8
, pp.
2287
–
2293
.
19.
Lee
,
N. K. S.
,
Cai
,
Y. M.
,
Wong
,
A. S. F.
, and
Joneja
,
A.
,
1997
, “
Ultra-High-Resolution Optical Monitoring System Using a Noise Cancellation Technique
,”
Opt. Eng.
,
36
, No.
12
, pp.
3353
–
3359
.
20.
Greenwood
,
J. A.
, and
Williamson
,
J. B. P.
,
1996
, “
Contact of Nominally Flat Surfaces
,”
Proc. R. Soc. London, Ser. A
,
295
, pp.
300
–
319
.
21.
Greenwood
,
J. A.
, and
Tripp
,
J. H.
,
1967
, “
The Elastic Contact of Spheres
,”
ASME J. Appl. Mech.
,
34
, pp.
153
–
164
.
22.
Nuri
,
K. A.
,
1974
, “
The Normal Approach Between Curved Surfaces in Contact
,”
Wear
,
30
, pp.
321
–
335
.
23.
Kagami
,
J.
,
Yamada
,
K.
, and
Hatazawa
,
T.
,
1983
, “
Contact Between a Sphere and Rough Plates
,”
Wear
,
87
, pp.
93
–
106
.
24.
Yip
,
F. C.
, and
Venart
,
J. E. S.
,
1971
, “
An Elastic Analysis of the Deformation of Rough Spheres, Rough Cylinders and Rough Annuli in Contact
,”
J. Phys. D: Appl. Phys.
,
4
, pp.
1470
–
1486
.
25.
Webster
,
M. N.
, and
Sayles
,
R. S.
,
1986
, “
A Numerical Model for the Elastic Frictionless Contact of Real Rough Surfaces
,”
ASME J. Tribol.
,
108
, No.
3
, pp.
314
–
320
.
26.
Lo
,
C. C.
,
1969
, “
Elastic Contact of Rough Cylinders
,”
Int. J. Mech. Sci.
,
11
, pp.
105
–
115
.
27.
Kagami
,
J.
,
Yamada
,
K.
, and
Hatazawa
,
T.
,
1986
, “
Contact Width and Compliance Between Cylinders and Rough Plates
,”
Wear
,
113
, pp.
353
–
370
.
28.
Poon
,
C. Y.
, and
Sayles
,
R. S.
,
1994
, “
Contact Analysis of a Smooth Ball on an Anisotropic Rough Surface
,”
ASME J. Tribol.
,
116
, pp.
850
–
859
.
29.
Fung
,
A. K.
, and
Chen
,
M. F.
,
1985
, “
Numerical Simulation of Scattering from Simple and Composite Random Surfaces
,”
J. Opt. Soc. Am. A
,
2
, No.
12
, pp.
2274
–
2284
.
30.
Yisok
,
Oh
,
1997
, “
Precise Estimation of Surface Parameters from Field-Measured Ground Truth Data
,” IEEM, 1997, IGARSS’97, 1997 International Geoscience and Remote Sensing Symposium, Remote Sensing -A Scientific Vision for Sustainable Development (Cat. No. 97CH36042),
IEEE
,
2
, pp.
708
–
710
.
31.
Whitehouse
,
D. J.
, and
Archard
,
J. F.
,
1970
, “
The Properties of Random Surfaces of Significance in Their Contact
,”
Proc. R. Soc. London, Ser. A
,
316
, pp.
97
–
121
.
32.
Ackerson
,
D. S.
, and
Harry
,
D. R.
,
1985
, “
Theory, Experimental Results, and Recommended Standards Regarding the Static Positioning and Orientation Precision of Industrial Robots
,”
Rob. Comput.-Integr. Manufact.
,
2
, Nos.
3/4
, pp.
247
–
259
.
33.
Lau
,
W. S.
, and
Ng
,
K. L.
,
1982
, “
Experimental and Statistical Determination of the Static Position Repeatability and a Recommended Specification for a SCARA Robot
,”
Rob. Comput.-Integr. Manufact.
,
9
, No.
3
, pp.
247
–
253
.
34.
Montgomery, D. C., 1996, Introduction to Statistical Quality Control, 3rd Ed. Wiley, New York.
35.
Lee, K. S., Joneja, A., Chan, K. L., and Chiu, K. H., 1998, “
Development of Automated Mechanical Alignment System with μm Repeatability,” private communication.
Copyright © 2001
 by ASME
You do not currently have access to this content.