integrating qfd and triz for innovative design
TRANSCRIPT
Bulletin of the JSME
Journal of Advanced Mechanical Design, Systems, and ManufacturingVol.11, No.2, 2017
Paper No.17-00019© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Integrating QFD and TRIZ for innovative design
1. Introduction and State of the Art
Sustainability is a challenge that requires an integrated approach to link the community’s economy, environment
and society. Many attempts to explain the concept of sustainability has led to different meanings of the same concept,
depending on the field of application as human, social, ecological, biological, industrial etc. In 1987 the Brundtland
Commission defined first sustainability as “meets the needs of the present without compromising the ability of future
generations to meet their own needs” (WCED, 1987 and Rosen, Hossam and Kishawy, 2012) .
In the engineering context, the sustainable development refers to advances in technology, economics, environment,
health and welfare. Traditionally, good strategies for manufacturing were considered increasing the volume of
production, reducing the time and costs (Hayes and Wheelwright, 1979). Nowadays, concerns as environmental
implication and use of natural resources strongly influence the manufacturing strategies choice, also in the preliminary
design phases.
Emerging design strategies are the Design for Environment and Life Cycle Assessment, the Resource and Energy
Sustainability, the Design for Sustainability, the Design for Disassembly (Francia, Caligiana and Liverani, 2016),
whose focus is to conceive a product by taking care of all the effect that its use can cause to the economy, to the society
and to the environment, also at its disposal.
In order to support sustainability in manufacturing, this paper presents an enhancing automatic process for direct
open moulding manufacturing. Open moulding is a process suitable for parts that require wide range of size part, large
and complex shapes, low-volume and rate of few thousand parts per year. In this process, raw materials (resins and
fibre reinforcements) are deposited on a mould through different processes, including hand lay-up, spray-up, casting,
and filament winding and then they are exposed to air as they cure or harden.
This technique allows for a rapid product development cycle because the tooling fabrication process is simple and
relatively low cost because of low cost tooling option.
On the other hand, all the open moulding processes are manual, slow and labour consuming and require the mould
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Gianni CALIGIANA*, Alfredo LIVERANI*, Daniela FRANCIA*, Leonardo FRIZZIERO* and Giampiero DONNICI* *Department of Industrial Engineering, ALMA MATER STUDIORUM University of Bologna
v.le Risorgimento, 2 Bologna I-40136, Italy
E-mail: [email protected]
Received: 10 January 2017; Revised: 23 March 2017; Accepted: 21 April 2017
Abstract Sustainable design aims at the creation of physical objects, environment and services that complies to optimize social, economic, and ecological impact. QFD is able to assess the product design by the choice and definition of parameters that can be qualitatively discussed. The purpose of design is to meet a need in new ways and in innovative ways. In this context, the QFD aims at evaluating the quality of a design process. TRIZ is a design method that aim at defining and overcome some critical issue that can affect the development of a product, by means of potential innovative solutions. In this paper QDF and TRIZ analysis have been adopted in order to validate a design method for direct open moulds, by a new strategy: hybrid manufacturing can reduce the production time, the use of material, the energy and the waste consumption, employing subtractive and addictive techniques efficiently combined.
Key words : Hybrid manufacturing, Additive, Subtractive, Direct open mould, QFD, TRIZ
2© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Caligiana, Liverani, Francia, Frizziero and Donnici,Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.11, No.2 (2017)
preparation by means of a model. The mould should be as accurate as possible and it reproduce the final part as the
design project describes. Furthermore, the entire process reveals not time-cost efficient and hazardous in terms of
harmful emission because in the open mould processes volatile organic compound (VOC) is pretty high (U.S.
Environmental Protection Agency, 1995). This is the reason why, in order to improve air quality, the open mould
process has been converted to closed mould process (U.S. Environmental Protection Agency, 1995 and OSHA, 1993)
that allows the fabrication of parts with complex geometry (Felix, Merritt, and Williamson, 1996) and accounts for
environmental protection, but requires more expensive tooling.
Direct open moulding does not require the model preparation for the mould and starts processing the mould
directly, catching information about the piece to reproduce only by a digital model. Commonly, the CAD model
includes all the information necessary to give instruction to the CAM. Thus, the CNC processing can be elaborated in
order to directly machining a block of material, up to the final mould shape. This technique allows reducing the
material use, wastes and energy consumption.
The goal of this paper is to suit a solution that can integrate the advantages of direct open moulding with
sustainable design, in order to find the optimal trade-off between time and cost-effective manufacturing and the respect
of the environment and of the human labours.
Traditional design strategies may be inadequate to meet these two requirements, thus a customer-driven approach
has been evaluated in order to develop product and design quality in the manufacturing industry (Chan and Wu, 2002;
Akao and Mazur, 2003; Vinodh and Chintha, 2011). A QFD (Quality Function Deployment) plan has been developed in
this paper in order to improve the design of products/services according to the customer requirements. Relationships
between the technical process requirements have been evaluated through the morphological matrix. Then the
fundamental requirements have been determined and further analysed by means of the dependence/independence
matrix. QFD made it possible to translate the process requirements into design attributes, but some contradiction arises
from the QFD evaluation. Thus, in order to enhance the attributes arose from QFD, a systematic analysis based on the
Theory of Creative Problem Solving (TRIZ) has been developed in order to propose innovative solutions that meet also
the sustainable design principles. In literature, studies about the integration between QFD and TRIZ can be found. In
particular M. Mayda and H. R. Borklu, 2014, implemented a composed method using before TRIZ, to identify
innovative concepts, then QFD to meet customers’ needs (Mayda and Borklu, 2014). Moreover, also C.H. Yeh, C. Y.
Huang Jay, C.K.Yu, 2011, developed a case study for the integration of QFD and TRIZ. In comparison with previous
authors, they have developed the first method using a four phase QFD plan, followed by TRIZ application to enable the
development of breakthrough products.
In this paper a new method is presented that is inspired to the direct moulding and that eliminates manual
operations by the introduction of an automatic process that combines additive and subtractive techniques to enhance the
fabrication of mould for direct open moulding.
2. QFD Approach to Solve the Open Mould Production
2.1 QFD
An important industrial methodology to give a direction to information flow is Quality Function Deployment
(Q.F.D.), which is often employed to come along with design development. QFD is a way to transform customers’
desires into suitable businesses’ requirements at every step, from research through production design and development,
to manufacture, distribution, installation and marketing, sales and services. This method was developed to bring
customized characteristics to innovative production and development processes. QFD aids designers seeking both
spoken and unspoken desires, translating these into actions and designs, and focusing various business functions toward
attaining at this common purpose.
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2© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Caligiana, Liverani, Francia, Frizziero and Donnici,Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.11, No.2 (2017)
The method is composed as follows (fig. 1):
Fig. 1. QFD’s flow
In particular:
1. Considering the clients’ requirements;
2. Clarifying quality systems thinking + psychology + knowledge/epistemology;
3. Taking full advantage of positive quality to add value;
4. Realizing comprehensive quality system for customers’ satisfaction;
5. Creating strategy to stay ahead of the competitive game.
QFD starts with the explanation of the task that can be summarized as the following scheme (fig. 2):
Fig. 2. Evaluation of the task development
Then, when the definition of the technical requirements is reached, it will be assumed to design the product. After the
explanation of the task, the problem is completely defined. Analysis of the environment and Six questions are part of the
explanation of the task.
Analysis of the environment: understanding the positioning of the new product and its innovative requirements.
Analysis of the competitors’ products: understanding the competitors similar products and the way to improve them.
Six questions: the six questions help immediately to extrapolate those requirements that must be embodied by
the object to be designed. They are (Table 1):
Analysis of
market
environmen
Analysis of
competitors
The six
questions to
describe
The
evaluation
matrixes
EVALUATION OF THE TASK
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2© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Caligiana, Liverani, Francia, Frizziero and Donnici,Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.11, No.2 (2017)
Table 1. QFD Six Questions
QFD QUESTIONS EMBODIMENT
1 WHO who uses our product?
2 WHAT what is the use of the product?
3 WHERE where is it used?
4 WHEN when is it used?
5 WHY why is it used?
6 HOW how is it used?
Evaluation and interrelation matrixes. Evaluation matrixes can be used in a double way. To estimate relative
importance or independence relationships among requirements, just like those defined above, the interrelation
evaluation matrix is used.
The interrelation matrix is an instrument evaluating the relationships of dependency (first use) and/or of relative
importance (second use) among various necessities or ideas; the instrument is used also to explain priorities and to
establish the best arrangement of activities.
In the first practice, the variables on the columns must be considered as the causes and the same ones, on the rows, as
the effects.
The dependence between the requirements can be none, weak, medium or strong.
It can be amountable, for example, with the following conventional values (Table 2):
Table 2. Dependence chart values
Value Dependence
0 None
1 Weak
3 Medium
9 Strong
Instead, in the second practice, the matrix is employed to estimate relative importance among all the variables. For the
relative importance analysis, the following conventional votes are used (Table 3):
Table 3. Importance chart values
1 if the row element has the same importance of the column one
0 if the row element is most important than the column one
2 if the column element is most important than the row one
All the votes can be obtained by market analysis upon a large sample of people.
Through the matrix employment, it is easy to understand that the highest values of the sums per rows specify which is
the most important variable among all of them (i.e. those which have more influence on the others).
Finally, after explanation of the task, the conceptual design starts at first, followed by the constructive one. In this paper
the investigation has been made among five researchers of the Design and Methods Research Group of the University
of Bologna. The design study is obtained through the Morphological Matrix (Freddi, 2002 and Shingley, Mische,
Budynas , 2005) and the conceptual CAD drawings.
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2© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Caligiana, Liverani, Francia, Frizziero and Donnici,Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.11, No.2 (2017)
2.2 QFD vs Open Mould Production
2.2.1 Six questions
Applying the six questions to the case of the Open Mould Production, the team were able to give the following answers,
in order to find out the requirements to be analysed (Table 4):
1) Who: who uses the open mould? who produced the open mould ? The open mould is used by companies producing
shell components. It is produced through industry processes.
Requirements (after discussion): INDUSTRIABLITY; WORKABILITY; RELIABILITY.
2) What: what is the use of the open mould? The open mould needs to produce industrial components.
Requirements (after discussion): INDUSTRIABLITY; WORKABILITY; RELIABILITY.
3) Where: where is the open mould produced/used? It is produced inside industrial mould production departments and
it is used in industrial production.
Requirements (after discussion): INDUSTRIABLITY; STRUCTURAL STRENGHT; THERMAL RESISTANCE.
4) When: when is the open mould produced? It is produced on customer request; it is usually available not before than
six months.
Requirements (after discussion): CUSTOMIZATION; PRODUCTION SPEED; PRECISION.
5) Why: why is the open mould used? It is used for giving a shape to products; often to give a complex shape.
Requirements (after discussion): COMPLEX SHAPE; CUSTOMIZATION.
6) How: how is the open mould used/produced? It can be composed by several parts; it can be used matched with a
machine.
Requirements (after discussion): PRODUCTION SPEED; STRUCTURAL STRENGHT.
Table 4. Requirements detection from six questions
Six Questions Requirements detected
WHO - Industriability
- Workability
- Reliability
WHAT - Industriability
- Workability
- Reliability
WHERE - Industriability
- Structural Strength
- Thermal Resistance
WHEN - Customization
- Production Speed
- Precision
WHY - Complex Shape
- Customization
HOW - Structural Strength
- Production Speed
From these answers, nine most important characteristics, which the open mould has to own, have been identified:
1. Industriabilty - 2. Structural Strength - 3. Customization - 4. Production Speed - 5. Workability - 6. Precision - 7.
Thermal Resistance - 8. Complex Shaping - 9. Reliability.
2.2.2 The evaluation matrixes
The interrelation matrixes are shown below (Tables 5-6); they are employed in both types of use for the open
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2© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Caligiana, Liverani, Francia, Frizziero and Donnici,Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.11, No.2 (2017)
mould, where the above mentioned requirements, obtained by the six-answers analysis, have been introduced.
Analyzing the matrixes, QFD parameters were defined as:
1) Industriability - 2) Structural Strength - 3) Customization - 4) Precision
These parameters can be linked in order to define the final project proposal. The connection is reached through the
morphological matrix (Table 7) in which, for each requirements evidenced by the previous analysis, four possible
technical solutions have been proposed.
The combinations of requirements traced a feasible quality assisted project path.
Table 5. The relative importance evaluation matrix
Table 6. The independence/dependence evaluation matrix
Relative importance
matrixIndustriability Structural Strenght Customization Production Speed Workability Precision Thermal Resistance Complex Shaping Reliability
Industriability 1 1 2 1 1 1 0 1 1
Structural Strenght 1 1 1 0 1 1 0 1 1
Customization 0 1 1 1 1 1 0 1 0
Production Speed 1 2 1 1 2 1 0 1 0
Workability 1 1 1 0 1 2 1 1 1
Precision 1 1 1 1 0 1 0 1 1
Thermal Resistance 2 2 2 2 1 2 1 2 2
Complex Shaping 1 1 1 1 1 1 0 1 1
Reliability 1 1 2 2 1 1 0 1 1
Importance 9 11 12 9 9 11 2 10 8
Indipendence/
Dependence
Matrix
Industriability Structural Strenght Customization Production Speed Workability Precision Thermal Resistance Complex Shaping Reliability DEPENDENCE
Industriability 1 9 9 1 3 1 3 9 36
Structural Strenght 0 1 1 3 3 1 3 3 15
Customization 3 9 3 9 3 1 9 1 38
Production Speed 9 1 9 9 9 3 9 3 52
Workability 3 1 3 1 1 9 1 1 20
Precision 9 3 3 9 3 1 3 1 32
Thermal Resistance 0 3 1 3 1 1 0 1 10
Complex Shaping 9 9 3 3 3 3 1 3 34
Reliability 9 9 3 3 1 3 3 3 34
INDIPENDENCE 42 36 32 32 30 26 20 31 22 271
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2© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Caligiana, Liverani, Francia, Frizziero and Donnici,Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.11, No.2 (2017)
Table 7. The morphological matrix
The technical solutions path has been suggested by the application of other relative importance evaluation matrixes, for
each line (requirements vs technical solutions) (Tables 8, 9, 10, 11).
Table 8. The relative importance evaluation matrix for “Industriability”
Table 9. The relative importance evaluation matrix for “Customization”
Industriability CNCADDICTIVE
MANUFACTURINGManual Work
Other Technologies
(For ex. Electric
Erosion)
CNC 1 2 0 0
ADDICTIVE
MANUFACTURING0 1 0 0
Manual Work 2 2 1 2
Other Technologies (For
ex. Electric Erosion)2 2 0 1
TOTAL 5 7 1 3
CustomizationComplex
ShapeAdvanced Material
Dedicated
TechnologySpecific Architecture
Complex
Shape1 1 0 0
Advanced Material 1 1 0 1
Dedicated Technology 2 2 1 1
Specific Architecture 2 1 1 1
TOTAL 6 5 2 3
MORPHOLOGICAL
MATRIX
TECHNICAL
SOLUTIONS 1
TECHNICAL
SOLUTIONS 2
TECHNICAL
SOLUTIONS 3
TECHNICAL
SOLUTIONS 4
Industriability CNCAdditive
ManufacturingManual Work
Other Technologies
(For ex. Electric
Erosion)
CustomizationComplex
ShapeAdvanced Material
Dedicated
TechnologySpecific Architecture
PrecisionMaterial
characteristics
Bi-layer
ArchiectureWorkabilty
Structural and
thermal strenght
Structural StrenghtStructure/
Frame
Architecture/
AssemblyMaterial Shape
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2© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Caligiana, Liverani, Francia, Frizziero and Donnici,Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.11, No.2 (2017)
Table 10. The relative importance evaluation matrix for “Precision”
Table 11. The relative importance evaluation matrix for “Structural Strenght”
Finally, switching from the conceptual analysis to the technical design study, the proposed concept of open mould can
be outlined, as depicted in figure 3 that follows.
Fig. 3. QFD concept of open mould
In order to refine the conceptual design for direct open moulding, this technical solution, suggested by QFD, can be
submitted to TRIZ analysis for a further optimization, in order to enhance innovative aspects.
PrecisionMaterial
characteristics
Bi-layer
ArchiectureWorkabilty
Structural and
thermal strenght
Material
characteristics1 2 0 1
Bi-layer
Archiecture0 1 0 1
Workabilty 2 2 1 2
Structural and thermal
strenght1 1 0 1
TOTAL 4 6 1 5
Structural StrenghtStructure/
Frame
Architecture/
AssemblyMaterial Shape
Structure/
Frame1 0 0 1
Architecture/
Assembly2 1 0 1
Material 2 2 1 1
Shape 1 1 1 1
TOTAL 6 4 2 4
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2© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Caligiana, Liverani, Francia, Frizziero and Donnici,Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.11, No.2 (2017)
3 TRIZ Approach to Find the Innovative Solution
A dedicated software for TRIZ problem analysis (Altshuller, 1994; Frizziero and Ricci Curbastro, 2006;
Terninko, J., Zusman, A., Zlotin, 1996), TechOptimizer®, has been employed for the analysis of the open mould. This
way, the computing power of a PC allowed reducing the time of analysis, despite executing manual operations.
The first task of this method is the formulation of the “Ideal Final Result”, the final objective of the work, the best one
among the possible solutions. Then, from this ideal starting point, it is possible to deploy a functional analysis and
moving backwards towards less ideal but more workable solutions. The analysis began first by the assumption of a
mould with three layers: a structural strength frame, the intermediate support in a light and easily workable material, a
complex shape additive layer easy to be shaped and to be finished. This is a feasible “Ideal Final Result”.
In the environment "Product Analysis" are provided in input the objectives to be achieved and the problem limitations
(Fig.4). These data have been captured from previous QFD analysis. For each requirement, the relative importance has
been evaluated on a scale from 1 to 10.
The program allows to build a chart in which are placed all the relationships between the different parts that compose
the mould and all operators that are involved. It was built a functional diagram (Fig.5) in which each relation can be
described as good or harmful; then, it was necessary to set each relation to make it interacting with parameters of the
mould, project parameters and so on.
Fig.4. The Product Analysis
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2© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Caligiana, Liverani, Francia, Frizziero and Donnici,Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.11, No.2 (2017)
Fig.5. TRIZ analysis
The following step consists in defining the same relationships and the data can be inserted both in qualitative and
quantitative manner. Additional information to be included are about the interaction with the parameters entered at the
beginning of the analysis. Finally, the software process consists in the launch of the command "Trimming". The
"Trimming" is a tool that allows to optimize the problem in order to choose the optimal path and architecture of the
project, eliminating negative components and actions. In particular in Fig. 6, we can see how the TRIZ-software
reached to optimize the structure of the Fig. 5: adding information about the relationships among each stakeholders in
the graph, keeping into consideration also the actions that each actor could make, TechOptimizer® gives us a schematic
result about how the new architecture of the open mould would be. In particular, comparing the two figures, we can see
that also in theoretical way, design method suggest us to eliminate one of the three architectural level, eliminating the
one relative to “structural strength frame”, and integrating it in the second one, i.e. “intermediate support”.
This result can be declined into the CAD study as we can see in Fig 7.
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2© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Caligiana, Liverani, Francia, Frizziero and Donnici,Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.11, No.2 (2017)
Fig.6. Results of Trimming
The TRIZ analysis leads to a first result: it reduces the mould layers from three to two ones. TechOptimizer®
optimised the solution by the elimination of the strength frame and by the transfer of its mechanical function to the
intermediate support. Thus, the innovative solution is a bi-layered architecture composed of a self-sustaining (former
intermediate) support and a complex shape additive layer (Altshuller, 1994; Frizziero and Ricci Curbastro, 2006;
Terninko, J., Zusman, A., Zlotin, 1996; Ko and Kim, 2012).
Thus, the innovative solution is a bilayered architecture composed of a self-sustaining (former intermediate) support
and a complex shape additive layer (Fig. 7):
Fig.7. Conceptual Solution after Trimming
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2© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Caligiana, Liverani, Francia, Frizziero and Donnici,Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.11, No.2 (2017)
Now, referring again to fig. 3, comparing with fig. 7, we can see that initially (fig.3), the architecture proposed was
formed by three levels, i.e. one frame for structural strength, one layer obtained by subtractive manufacturing for
interfacing between precision customization level and frame, one layer obtained by additive manufacturing for
precision and customization. Then, after QFD+TRIZ analysis, we arrive at an optimization, that we can call properly
“Technical Optimization”, in which we assist at the simplification of the three levels structure to a two levels structure,
that means having only one layer obtained by subtractive manufacturing and functioning as a frame, and one layer
obtained by additive manufacturing for precision and customization. The results of QFD+TRIZ integrated method
gives us a technical solution reducing complexity in the final architecture of the open mould.
4. A new method integrated
Following the QFD and TRIZ analysis before mentioned, we can affirm that from the integration of QFD and
TRIZ innovative solutions arises a proposal of a new design method for the manufacturing of direct open moulds as
shown in the following picture (fig. 8), considering that QFD (and Integration Method) Input are “Customers’ Needs”.
Then Output will be generated as “Architecture Opimized”.
Fig.8. QFD-TRIZ Integration Method
5. Results: the Hybrid 3D Manufacturing and the 3D Printer
The analysis of both QFD and TRIZ suggested an innovative architecture for direct open mould
manufacturing that could account for rapid processing time, accuracy of dimensional tolerances and roughness of
surfaces, automatization of the process and low material consumption, in order to optimize the manufacturing process.
All these requirements can be satisfied by a new system based on a bi-layered architecture. The new mould should be
composed by a self-sustaining support, realized in light and cheap material, and a complex shape additive layer that has
to accurately reproduce the surface of the mould suitable to shape the target piece.
This solution comply with the functionality of open mould. In open moulding, only few surfaces of the entire mould are
useful to the part lamination and only these ones need to conform to specific roughness ad dimensional tolerances.
The remaining volume of the mould does not require particular accuracy and it can be roughly shaped. Thus, the
QFD+TRIZ method outcome of a bilayer mould could be achieved by providing an inner support of rough material and,
upon it, the deposition of a thin bed of plastic material that has to follow the shape of the mould.
In order to improve the industriability and the precision of the process, it could be advisable to automatize the
additive/subtractive operations.
Figure 9, that follows, shows how to set up a bilayer structure for the mould, realized by milling and addictive layering
that can be refined by finishing operations, starting from a target piece.
QFD TRIZ
Requirements
Architecture
Architecture
Optimized
QFD Output – TRIZ Input TRIZ (Integration
Method) Output
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2© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Caligiana, Liverani, Francia, Frizziero and Donnici,Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.11, No.2 (2017)
Fig.9 The bilayer architecture of an open mould and the hybrid process required for its manufacturing
In the laboratories of the Department of Industrial Engineering, University of Bologna, a 5-axis hybrid 3D printer has
been assembled (fig. 10). It is able to work as additive and subtractive manufacturing system at the same time by a
head/nozzle replacement for both milling and addictive manufacturing, managed by a software (PrinterCAD) able to
integrate a 3D slicer and a CNC/CAM module with the CAD software.
The system spans over a huge volume (5x3x2 m) and may be equipped by a nozzle in order to spray a film coat on the
surface. Through a very user-friendly interface, the user can choose a process, can simulate it and then can make the
system working.
Through a very user-friendly interface, the user can choose a process, can simulate it and then can make the system
working (Caligiana, Francia and Liverani, 2016).
Fig.10. The Hybrid 3D printer own in the laboratories of the University of Bologna
5.1 Sustainability points of the method: CAD-CAM integration in the case-study of PrinterCAD
PrinterCAD is the H3DP’s project at the University of Bologna: it includes a 3D slicer and a CNC/CAM module, fully
integrated with the CAD software.
The project PrinterCAD aimed to enhance the flexibility of production in terms of sizes, accuracy and functionality of
products. The system is able to work as additive and subtractive manufacturing system at the same time: the software is
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2© 2017 The Japan Society of Mechanical Engineers[DOI: 10.1299/jamdsm.2017jamdsm0015]
Caligiana, Liverani, Francia, Frizziero and Donnici,Journal of Advanced Mechanical Design, Systems, and Manufacturing, Vol.11, No.2 (2017)
written as open source and is able to translate and interconnect different programming languages, in order to coordinate
different functions of the system.
The hybrid process begins with the modelling of a part by means of a CAD software. This open source software has
been developed starting from the FreeCAD architecture. Then a milling module has been integrated into the system to
manage the subtractive process, based on the FreeMILL architecture. Finally, the slicing module has been compiled in
order to give instructions to the RP machine to produce the desired part.
Depending on the assigned part, additive and subtractive techniques can be interchanged. A part could be produced by
additive deposition and then could be milled, in order to reach more accurate shape or dimensions, or it can be prepared
starting from a block of raw material, different from the material of the part, and, upon it, the final material can be
added. This way, the shape can be obtained only by the deposition of few layers upon an inner core. Depending on the
attainable shape of the part and on its material, a spray technique can be adopted in order to realize a 3D deposition.
The methodology is resumed in Figure 11 that follows (Francia et al. 2017).
Fig. 11. The hybrid manufacturing process that combine addictive, deductive and spray deposition.
The main purpose of this project is to manage in a single environment and at low cost, many aspects: to be able to
handle 3D printing and CAM operations in an economic environment, with open source tools, extension of CAD and
CAM programs. FreeCAD’s environment has been extended and integrated with the 3D printing software (Slic3r) and
CAM module (FreeMILL). Repetier-Host, Hummingbird and OpenSCAM were provided for previewing the G-codes
(language for 3D printers) in order to provide the system a visual feedback prior to the RP process and to prevent
damages of the printer.
Finally, an emulator of the hybrid 3D printer, the MTX Indramotion Rexroth Bosh, has been integrated too.
5. Conclusions
In this paper, QDF and TRIZ analysis have been investigated in order to validate a design method for direct
open moulds, by a new strategy that intends to combine additive and subtractive manufacturing in order to obtain an
innovative product. The work was developed through the following steps: 1. QFD analysis composed by Six-questions
analysis, evaluation matrixes and morphological matrix analysis; 2. Output of QFD analysis as Product Requirements
and Conceptual Product Architecture; 3. TRIZ analysis using as Input the above mentioned QFD Output; 4. final
optimized solution QFD&TRIZ achieved (fig. 7).
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