| Sustainable manufacturing of high quality products is the top priority at leading companies in the global marketplace. In the automotive and aerospace industries, the negative impact or burrs and particulate contaminants (manufacturing byproducts) on product performance, reliability, and scrap rate is increasing rapidly clue to the complexity and precision of new designs. In addition, natural resources---most notably energy and water---consumed by deburring and cleaning processes have increased. This dissertation presents strategies to incorporate cleanability-conscious product design and manufacturing process planning along the different stages of the design-to-manufacturing value chain, aimed at increasing the efficiency of cleaning operations such as high-pressure waterjets. To support the development of computer-aided cleaning simulations, two new measurement methods are introduced---the embedded sand method and the patterned surface method---that are capable of measuring, in a continuous range, the influence of key geometric and kinematic parameters of high-pressure waterjets on cleaning effect.; Motivated by the need for more accurate burr minimization process planning strategies applicable to milling of new Al-Si alloys in automotive production, algorithms for the calculation of Exit Order Sequence (EOS) of the cutting edges and Tool Engagement (TE) along the contours of solid models are developed. A detailed survey of prior burr minimization research and the execution of milling experiments on Al-Si alloys used in current-generation powertrain components evidences that identification of burr formation mechanism can greatly enhance the predictive power of the EOS and TE kinematic models when used in tandem with empirical burr morphology control charts, constructed from burr height data for each workpiece material as a function of depth of cut and engagement angles. |
