Hindawi Publishing Corporation
Advances in Mechanical Engineering
Volume 2013, Article ID 702590, 10 pages
http://dx.doi.org/10.1155/2013/702590
Research Article
Integrated Knowledge-Based System for Machine Design
DurmuGKarayel,1 S. Serdar Ozkan,1 and Fahri Vatansever2
1 Sakarya University, Sakarya, Turkey
2Uludag University, Bursa, Turkey
Correspondence should be addressed to S. Serdar Ozkan; sozkan@sakarya.edu.tr
Received 22 April 2013; Revised 6 August 2013; Accepted 16 August 2013
Academic Editor: Dongxing Cao
Copyright © 2013 Durmuş Karayel et al.This is an open access article distributed under theCreativeCommonsAttribution License,
which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
An integrated design system (IDS) approach has been developed to integrate various stages of the mechanical design process,
including rapid prototyping. The system consist, of design, analysis, calculation, rapid prototyping, and library modules, and it
blends artificial intelligence methods, CAD-CAM, and technical computing packages into a single environment. The system has
been applied for the design of one-stage gearbox with helical gear. In this case study, all stages of the design process are carried out
by using IDS.
1. Introduction system, which describes parametric modeling with design
knowledge-based [5]. Ramamurti et al. put forward an
The design process of the mechanical products is tedious and integrated system that could be used by the user for the
time consuming because of the various stages and complex complete design and analysis of a mechanical system. The
activities involved. On the other hand, there are strong pres- system consists of two parts, such as initial design and
sures to reduce overall costs in a competitive market environ- detailed analysis [6]. Zha and Du presented an integrated
ment [1]. But, the traditional design approach is inadequate in method and assembly planning. They applied the system as
meeting these needs. Today a lot of CAD/CAM/CAE applica- an integration model, and so, CAD/CAM applications in
tion software, different databases, and web-based services are assemblywere supported [7]. Chiang et al. proposed a general
used for themechanical design studies, but these technologies integrated framework of design knowledge representation
are distributed and there is no coordination between them. and developed a knowledge-based intelligent system to facil-
Therefore, a number of researchers have focused their studies itate dynamic design reasoning. Also, they presented a case
on establishing a cooperative and integrated environment. study of designing a mechanical system to demonstrate the
Su and Wakelam studied an intelligent hybrid system for features of the developed system [8]. Chung et al. studied a
integration in design and manufacturing. Their approach framework for integratedmechanical design automation, and
blends a rule-based system, artificial neural networks, genetic they developed extended variational design technology using
algorithm, hypermedia, and CAD/CAE/CAM packages into graph theory and numerical solution techniques [9]. Liang
a single environment [2]. Zhao et al. described an agent- and O’Grady studied the object-oriented approach. Their
based approach to systems interoperability in cooperative study contained both of the fundamentals of object-oriented
design systems [3]. Hao et al. developed an agent-based design in the development of design process models [10]. Zha
collaborative e-engineering environment for product design et al. proposed a knowledge-based approach and developed
engineering. They studied a prototype software system based an expert design system to support top-down design for
on the web and a software agent and demonstrated its assembled products. The proposed approach focused on the
viability through an industrial case study [4]. Myung and integration of product design, assemblability analysis and
Han introduced the feature representation, a concept of evaluation, and design for assembly with economical analysis
design unit, parametric modeling, and configuration design [11]. Chen et al. developed an intelligent approach for generat-
methods, and they proposed a framework of a design expert ing assembly drawings automatically from three-dimensional
2 Advances in Mechanical Engineering
computer assembly models of mechanical products by simu- design model for extending the scope and deepness of its
lating the experienced human designer’s thinking mode with application [21]. Jia et al. proposed a novel multilevel system
the aid of computer graphics and a knowledge-based expert representation modeling framework for supporting design
system [12]. Daabub and Abdallah presented a computer methods.Their framework had the capability to integrate the
based intelligent system so that the design for assembly can be product design CAD models. Also, the data exchange and
realized within a concurrent engineering environment. They transfer inmultidomain analysesweremade possible by using
developed an expert system that supports new techniques for the framework. The authors illustrated the framework with a
design and for assembly, and the developed system gave users case study. So, the applicability of the modeling framework
the possibility to assess and reduce the total production cost was highlighted for multibody mechanical systems [22]. Li et
at an early stage during the design process [13]. Wang et al. al. discussed an integrated design method, which thoroughly
described a new framework for collaborative design. This considers related parameters of the various subsystems in
framework adopts an agent-based approach and relocates order to optimize the overall system that mainly consists
designers, managers, systems, and the supporting agents of optomechanical structure CAD, CAE, and the integrated
in a unified knowledge representation scheme for product information platform PDM. Their method was based on
design [14]. Wang and Zhang aimed to develop a distributed the model transformation and data share among different
and interactive system, on which designers and experts can design and analysis steps, and so they carried out concurrent
work together to create, integrate, and run simulations for simulation and design optimization. Also, they presented
engineering design. Karayel et al. purposed an internet- an example of application of a mechanical structure [23].
based intelligent agent system for mechanical design [15]. Zheng et al. developed a novel collaborative design approach
The reference model and the architecture of the system to improving efficiency. They designed and implemented a
were developed [16]. The current study can be accepted prototype system CoAutoCAD to test the approach and to
as a detailed part of this general research. Karayel et al. demonstrate a variety of collaborative design activities [24].
studied to determine factors affecting safety stress in the Zhongtu et al. described a declarative modeling approach
machine design by using artificial intelligence technologies for task implementation and a methodology for problem-
[17]. Cao and Fu proposed and employed a design syn- solving of knowledge primitives in design task. In the study,
thetic approach to guide the design process via behavioral task analysis, knowledge management, and design object
reasoning and to obtain an iterative transforming process. management module were developed and integrated with
They presented the functional representations and design a mechanical computer-aided design (MCAD) system. The
parameters according to the design requirements of a product two-stage gearbox design was given as an example for this
and established a behavioral matrix model by using the bond approach [25]. Al-Ashaab et al. developed a knowledge-based
graph fundamental elements and then presented a knowledge environment (KBE) to support product design validation of
modeling language for behavioral reasoning.They developed refresh projects, and they implemented KBE on the product
a prototype system for a computer-aided conceptual design lifecycle management platform. This implementation pre-
and presented an application from the industry consequently vented repeating unnecessary and costly physical product
[18]. Cao et al. presented an agent-based approach for tests, and so it also reduced time and costs for these refresh
guiding the mechanical product conceptual design. Firstly, projects [26]. Chandrasegaran et al. aimed to review the
they analyzed the mechanical product design requirements product design process. They focused on a time frame of the
and then gave functional parameters and design variables last 20 years in general and the last decade more specifically,
and proposed a behavioral matrix model using bond graph in order to balance the breadth and depth of the review,
fundamental elements. After, they established an agent-based relaxing the time framewhere it was necessary to look further
framework and so aimed at solving the behavioral matrix in the past to establish relevance [27]. Rocca presented a
model, producing functional means tree and multisolutions broad technological review of knowledge-based engineering
with the aid of agent technologies. An application for the (KBE) in the attempt to fill the current information gap. In
special jig design in the machine center was presented as this study, the artificial intelligence roots of KBE are briefly
an example of the design synthesis [19]. Goel et al. analyzed discussed, and the main differences and similarities with
CAD dimensions, such as cognitive design, collaborative respect to classical knowledge-based systems and modern
design, conceptual design, and creative design. Then, they general purpose CAD systems are highlighted. Finally he
developed a knowledge-based CAD system illustrating CAD investigated evolution and trends of KBE systems and pro-
characteristics, and this systemwas called Design by Analogy vided a list of recommendations and expectations for the
to Nature Engine (DANE). They proposed that DANE is KBE systems of the future [28]. Chen et al. aimed to develop
an important assistant to assess the practical use of CAD a knowledge-based framework for the creative conceptual
dimensions. One of the major contributions of DANE is design of multidisciplinary systems through reusing and
to provide human interaction with knowledge-based CAD synthesizing known principle solutions in various disciplines
systems [20]. Chen et al. presented a multilevel model for together. The framework contained a formal constraints-
an entirely assembly design. Their model captured abstract based approach for representing the desired functions,
information, skeleton information, and detailed information, a domain-independent approach for modeling functional
so that it can effectively support assembly design. This knowledge of known principle solutions. The success of the
assembly design process contained design steps with an system was explained with a design case study [29]. Lee
assembly tree structure. They discussed the use of assembly et al. prepared a new and efficient collaborative intelligent
Advances in Mechanical Engineering 3
computer aided design (CAD) framework in a theoretical 2. Background of the Engineering
study. Their study made an effort for minimizing redundant Design Process
design stages and design bottlenecks using the design his-
tory, while a lot of collaborative CAD frameworks aimed Engineering design can be defined as the realization of a
at decreasing the waiting time for updating design among product which satisfies a certain need [17]. In other words,
collaborative designers. Also, it generated an efficient reverse- the first objective of any engineering design project is the
engineered process, while resolving other existing collabora- fulfillment of some human need or desire. Engineering may
tive design issues [30]. Wang et al. presented a new approach be described as a judicious blend of science and art, in which
of parametric collaborative design based on the analysis of the natural resources, including energy sources, are transformed
many disadvantages in serial design for concurrent engineer- into useful products, structures, or machines that benefit
ing and developed an overhead travelling crane’s parametric humankind [34]. It is a good design if its product works
collaborative design system for concurrent engineering. The efficiently and economically within the imposed constraints.
feasibility, availability, and effectiveness of the system were The major constraints are cost, reliability, safety, level of per-
validated by the results obtained from the case study [31]. formance, legal requirements, sociological considerations,
Wang et al. presented the solution of collaborative simulation pollution, and energy consumption. Also, engineering design
environment (CSE) and analyzed its function framework is not a process consisting of only one phase. On the contrary,
and system architecture. They researched multihierarchy it is an iterative process involving a series of decision-making
engineering data management (EDM) and simulation flow steps where each decision establishes the framework for the
control. Then, the flow model platform and web portal of next one. It is a continuum effort which embodies stages such
some suspension systems CSE were developed in the paper. as preliminary design, intermediate design, detail design,
Finally, they proposed that the product simulation periodwas and development. The engineering design process starts
shortened and the design efficiencywas increased [32]. Zhang with product specification and goes through an interactive
et al. proposed an intelligent design system for complex process of requirements analysis, conceptual design, detailed
mechanical product. The intelligent design system adopted design, and design analysis, and it ends with a functional
product family case tree to construct the model of complex product that fulfills the product specification [9]. Each stage
mechanical product and case-based reasoning technology to has submodules that are different from each other, and
reuse successful product design knowledge. Product design therefore a designer is not expected to be an expert on
system was constructed by using the engineering database all stages. However, a successful designer either should be
technology. After that, they realized the intelligent crane able to communicate effectively with various specialists in
design platform by Visual Basic.NET programming, and so, the different stages or should utilize an integrated system
saw that the application example demonstrated the feasibility consisting of expert systems corresponding to design stages.
of the approach [33]. The present study considers detail design and purposes to
This study is part of a comprehensive project which has develop an integrated design system.
many subsystems. Here, the general framework of the project
is described, and the integration of the subsystems is focused 3. Integrated Design System (IDS)
on.When all the processes about the project are completed, it
can operate as an intelligent interactive system. In this study, The IDS is the detail designmodule of themodel of integrated
the subsystems such as design, analysis, computation, and design system for mechanical design. The flow chart of
rapid prototyping are prepared, and each of them can fulfill its the IDS is in Figure 1 and its input screen is in Figure 2.
function now. It is an important prerogative of the study that The IDS involves submodules such as calculation, analysis,
the user can realize all the processes on a single platform.The modeling and drawing, rapid prototyping, and library as seen
users can utilize both subsystems individually and can utilize in Figure 3.
the whole system with little user intervention for now. On All modules are interactive with each other. The calcula-
the other hand, the system has a suitable structure for users tion module of the IDS is used for engineering calculation,
of all levels because all design and prototyping tools used in such as dimensions of machine elements and the calculating
the system are chosen from practical applications. This case of the design safety stress. The 3D modeling and 2D drawing
is a difference of the system too. At the same time, the system of the products can be prepared by using the design module
uses the current training materials; therefore, this study can of the IDS. This module uses CAD/CAM software packages
be used for the training of machine design with small adap- such as SolidWorks andCatia.The analysismodule of the IDS
tations. This also is another distinctive feature of this study. can perform the numerical analysis of the mechanical system
This study provides an intermediary to integrated different using finite element methods such as Abaqus and Ansys. The
engineering tools such as CAD/CAM packages, technical library module of the IDS consists of material database, stan-
computing and analysis packages, and databases and knowl- dard tables and diagrams, systematic technical knowledge
edge bases. This study is organized as follows: at first, an andfirmcatalogues and supports the othermodules.Thefinal
introduction and literature review are presented. Section two product of the design process can be transformed into a real
gives a background about the engineering design process. physical model by using rapid prototype module of the IDS.
Section three illustrates integrated design system (IDS).
Section four presents an implementation of IDS, and section Knowledge Representation and Data Transfer of Integrated
five describes the conclusions of the study and future works. Design System (IDS). Automatic data transfer between
4 Advances in Mechanical Engineering
Start
Enter username-password
No
Correct user?
Yes
Main module of programme
Select the process
Yes “Design” module
Design? SolidWorks,
Modeling and drawing Catia
No
Yes
Analysis? “Analysis” module Abaqus
No Finite element analysis
Yes “Calculation” module
Calculation?
Engineering calculation
No
Yes “Rapid prototyping” module
Rapid prototyping? ZPrinter 450
Production of real physical model
No
Yes “Library” module
Library?
Materials database, tables, diagrams, traceparts and technical knowledge
No
Stop
Figure 1: The flow chart of the IDS.
Figure 2: The input screen of the IDS.
the units has been carried out using the software agents. In the
study, software agents are programs that can perform specific
design tasks for a user and possesses a degree of intelligence
that permits it to perform parts of its task autonomously and
to interact with its environment in a useful manner. There
are software agents for each task, and so it can be possible
to transfer the knowledge and to use it collectively. The Figure 3: The user interface of the IDS.
communication and coordination between agents requires a
standard knowledge protocol. For this reason, the knowledge
exchange schemes and the knowledge forms have been who to whom, what is the purpose, and what is the answer.
prepared. The design knowledge is determined into specific The knowledge protocol layers, which are used by agents of
codes. This knowledge is categorized into main articles and mechanical design, consist of definition, query, and result
subarticles according to their themes. Also, the activities of layers.This knowledge protocol is presented in Figure 14. It is
knowledge exchange between agents have been categorized very important that the design knowledge must be prepared
and have been prepared into certain formats, such as from into suitable documents so that they can be converted to
Advances in Mechanical Engineering 5
Input shaft
Output bearing cap 1 Input bearing cap 1
Gear Pinion
Output bearing cap 2 Output shaft Input bearing cap 2
Figure 4: Layout of one-stage gearbox.
Figure 5: The calculation module of the IDS.
digital signals easily because the knowledge stream is in
digital form.Therefore, the documents which are the defining
address of the knowledge and its position number have been
prepared.
Figure 6: The screen of the gear pair.
4. Implementation of the Integrated
Design System
In this study, the design of one-stage gearboxwith helical gear Then, these are drawn according to the calculated dimen-
has been chosen as a design case study to illustrate and test sions. After, these elements are analyzed and the part dimen-
the developed system. The aim of this section is to use the sions are considered again in case of need.The assembly of the
developed system for the complete design and analysis of the gearbox is realized finally.The last stage of the design process
gearbox. The gearboxes are used to transmit power and to is prototyping the whole gearbox together with all the ele-
change speed, and these have an extensive application area ments. The use of the IDS has been described in accordance
such as materials handling, transportation, metallurgical, with the elements of the gearbox, which is shown in Figure 4.
and chemical engineering. Also, the gearboxes contain the
principal machine elements such as gears, shafts, bearings, 4.1. Gear Design. The design of the gear pair begins with the
bearing caps, bolts, and keys and represent a comprehensive calculation of the gear dimensions, and so the calculation
mechanical system. Therefore, the gearbox has been selected module has been selected fromGUI, and then a new window
for this case as an example. Figure 4 shows the layout of the is opened as seen in Figure 5.
gearbox. The calculation module consists of the dimension and
The graphic user interface (GUI) has been prepared to the design stress submodules. When the dimension module
allow the user to select the design stages (Figure 3). First, the is selected from here, second new window containing the
dimensions of each element of the gearbox are calculated. machine elements is open, as shown in Figure 6. Again,
6 Advances in Mechanical Engineering
methods of these shafts are the same as each other.Therefore,
one of these is described more in detail than the other. The
diameter of the shaft can be automatically calculated using
the dimensionmodule of IDS.When the axles and shafts icon
of this module is clicked, a new window is opened, as shown
in Figure 9. In this window, if the input parameters of the
shaft are written, the diameter of the shaft can be obtained.
The shafts are forced by the combined torsion and bending
load because these are required to transmit the torque, as well
as withstanding the bending stresses due to the gear teeth
loads and bearing reactions. The shafts are modeled as beam
elements, and so their diameters are calculated.The diameter
of the shaft (𝑑) is given by
Figure 7:The screen for the geometrical dimension and drawing of
the gears. 32 ⋅ 𝑀3 𝐵
𝑑 = √ , (3)
𝜋 ⋅ 𝜎
𝑒𝑚
the gears are selected from this window and the input data where𝑀 is combined moment and 𝜎 is safety stress. The𝐵 𝑒𝑚
of the gear pair are entered. combined moment consists of the bending moment 𝑀 and𝑒
In the calculation of the gear mechanism, the pinion has the twisting moment𝑀 and it is given by𝑏
been considered because it is forcedmore than the other gear.
The corresponding gear can be selected accordingly [6]. The 12 2𝑀 = √𝑀 + 𝑀 . (4)
𝐵 𝑒 𝑏
module of the gears (𝑚) is calculated using the equations 2
according to bending stress and contact stress as shown in
the following. 4.3. Bearing Design. The use of the radial ball bearing is
The module according to bending stress: suitable.The gearbox has two shafts as the input shaft and the
output shaft, and four bearings are required for these shafts.
cos Because the load is applied from the middle of the shaft, the𝑘 ⋅ 𝜁 ⋅ 𝑀 ⋅ 𝛾 ⋅ 𝛽
3 𝑏 𝑛 0
𝑚 = 6 ⋅ √ , (1) bearings belonging to the same shaft are forced with the same
𝑛1
𝑍 ⋅ 𝜎 ⋅ 𝜓 ⋅ 𝜀
1 𝑒𝑚 𝑝 loading value. Therefore, the bearings to be selected are two
types for the input shaft and the output shaft.Thebearings can
and the module according to contact stress: be selected by using the axles and shaft icon of the dimension
module of IDS, as seen in Figure 10.
4
𝑘 ⋅ 𝜁 ⋅ 𝑀 ⋅ 𝐸 (𝑖 + 1) ⋅ cos 𝛽 (2) When the bearing parameters are entered and the select3 𝑏 0𝑚 = 9 ⋅ √ .
𝑛2 icon is clicked, the calculation of the bearing is realized and
𝑍 ⋅ 𝑃 ⋅ 𝑖 ⋅ 𝜓 ⋅ 𝜀
1 𝑒𝑚 𝑝 the suitable bearing can be selected. For this process, the
The design of the gears is done in two steps: step 1 principal bearing equations used by the software of the IDS
is to determine the module and step 2 is to calculate the are as follows. For the deep grove ball bearing the equivalent
geometrical dimensions and drawing. The module of the dynamic load, 𝐹 is given by𝑒𝑠
gears can be easily determined when the input data of the
𝐹 = 𝑋 ⋅ 𝐹 + 𝑌 ⋅ 𝐹 , (5)
gear pair are entered and the standardmodule icon is clicked, 𝑒𝑠 𝑟 𝑎
as shown in Figure 5. The IDS calculates the module (𝑚) by where 𝑋, 𝑌, 𝐹 , and 𝐹 are radial factor, thrust factor, radial
means of (1) and (2). The system accepts the maximum of 𝑟 𝑎force, and axial force, respectively.
two values obtained from equations as the module (𝑚) and The basic dynamic load rating is
selects standard module. When the geometrical dimension
and drawing icon is clicked, the new window is opened for 3
𝐶 = 𝐹 √𝐿, (6)
entering geometrical data, as seen Figure 7. 𝑒𝑠
GearTrax is a submodule of the SolidWorks software where 𝐿 is life of bearing. Finally, IDS selects the suitable
package and is used for the geometrical dimension and bearing according to the diameter of the shaft and the
drawing of the gears. The designed gears are presented in dynamic load rating from the catalogue in the librarymodule
Figure 8. The design of shafts, the bearings, and the keys of the IDS.
is achieved in two stages, as the dimensional calculating
and geometrical forming. The geometrical forming of these 4.4. Key Design. When power is supplied from the rotating
elements depends on each other, and so this process is shaft, it is necessary to attach gears to the shaft. To prevent
postponed until the second stage. relative rotation between the shaft and the gear, the connec-
tion between the gears’ hub and the shaft must be secured
4.2. Shaft Design. There are two shafts belonging to the [35]. Here, the parallel key is used to prevent relative rotation.
pinion and the gear in the assembly of the gearbox.Thedesign Recommendations for key width and height, as a function
Advances in Mechanical Engineering 7
(a) (b)
Figure 8: The designed gears: (a) the pinion and (b) the gear.
Figure 9: The calculation screen of the shaft diameter. Figure 10: The screen for the selection and the design of the
bearings.
of shaft diameter, are provided by standards, as shown in SolidWorks is used for the current study, and the assembly
Figure 11. The key length (𝑙) is obtained as a function of of the gearbox into 3D is presented, as seen in Figure 13.
the transmitted torque. The key is forced by the shearing Due to pages limitation of the paper, the analysis and rapid
stress and the comprehensive bearing stress. Therefore, the prototyping module of the IDS could not be discussed.
calculation of the key length is based on these stresses. These However, the numerical analysis of the designed products can
processes about the key are realized by the dimensionmodule be carried out, and both the elements and the assembly of the
of the IDS, as shown Figure 11. gearbox can be produced as a prototyping by using ZPrinter
450 machine connected to the IDS.
4.5. Geometrical Forming and Assembly. The geometrical
forming of the parts of the gearbox and their assembly are 5. Conclusion
achieved by the design module of the IDS. This consists of
two submodules such as SolidWorks and Catia for present, as This study is the first part of a comprehensive project
seen in Figure 12. which has many subsystems. Here, the general framework of
8 Advances in Mechanical Engineering
From To
0101 0104
Aim Question Task
001 001
0 (question) 002 002
003 003
1 (answer)
2 (knowledge)
Knowledge Response Response
source status signal
D0104020803
D0104020301 01 01 (done)
. . .
. . .
. . . 02 02
00 00 (wait)
Figure 11: The screen for the key design.
Figure 14: The knowledge protocol.
can fulfill its function now. It is an important prerogative
of the study that the user can realize all the processes on
a single platform. The users can utilize both subsystems
individually and can utilize the whole system with little user
intervention for now. On the other hand, the system has a
suitable structure for users of all levels because all design
and prototyping tools used in the system are chosen from
practical applications. This case is a difference of the system
too. At the same time, the system uses the current training
Figure 12: The design module of IDS. materials; therefore, this study can used as a course tool for
the training of machine design if the small adaptations are
realized on the system.This also is another distinctive feature
of this study. Also, all stages of the design of the gearbox have
been achieved by using the IDS only, and so the IDS has been
tested. It is expected that the IDS will be a favorable computer
aided tool for industrial users because it reduces the design
cost, design errors, and time to market.The next works about
this subject will be focused on the intelligent features of the
system.
Nomenclature
𝑀 : Torsional moment, N⋅m
𝑏
𝐸: Elasticity module, Pa
𝛽 : Helix angle, radians.
0
Figure 13: The assembly of the gearbox. Subscripts
𝑘: Impact factor
𝜁: Dynamic load factor
the project is described and the integration of the subsystems 𝑍 : Number of teeth of gear
1
is prepared. When all processes related to the project are 𝜓: Dimension factor
completed, it can operate as an intelligent interactive system. 𝜀 : Engage ratio
𝑝
In this study, the subsystems such as design, analysis, compu- 𝛾 : Form factor
𝑛
tation, and rapid prototyping are prepared, and each of them 𝑖: Gear ratio.
Response layer Query layer Definition
Advances in Mechanical Engineering 9
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