Manufacturing Integrated Design (eBook)

Professor Groche is currently the Director of Institute for Production Engineering and Forming Machine (PtU) at Technische Universität Darmstadt in Germany. He is the recipient of numerous awards and fellowships, including the Hessian Cooperation reward. He has supervised over 200 Masters Theses and more than 35 Doctoral Theses.  He has served as the conference chairman for numerous conferences, including the 6th International Conference on Tribology in Manufacturing Processes & Joining by Plastic Deformation, and is a member of various scientific societies, including the International Academy for Production Engineering (CIRP).Dr. Bruder is a Postdoctroal Research Associate at the Materials Science Department, Physical Metallurgy Division, Technische Universität Darmstadt in Germany. He has served as a Visiting Lecturer at Brandenburg University of Technology in Cottbus, Germany, and a Visiting Scientist at the Centre for Advanced Hybrid Materials, Monash University in Melbourne, Australia.Dr. Gramlich is a Postoctoral research associate at the Institute for Product Development and Machine Elements, Technische Universität Darmstadt, Germany.

Preface 5
Contents 7
Contributors 9
Abbreviations 12
Symbols 14
Chapter 1: Introduction: Production Technologies and Product Development 18
1.1 The Interaction Between Product Development and Production Technology 18
1.2 Incorporation of Production in Current Product Development Approaches 19
1.3 Market Pull vs. Technology Push 23
References 25
Chapter 2: The CRC666 Approach: Realizing Optimized Solutions Based on Production Technological Innovation 27
2.1 Motivation for and Goals of a New Development Approach 27
2.2 Options in Manufacturing Technologies 29
2.3 Manufacturing-Induced Properties 33
2.4 Mathematical Optimization of Product Geometries and Manufacturing Processes 35
2.4.1 Classification of Optimization Tasks 37
2.4.2 Examples for Optimization 40
2.5 Integrated Algorithm-Based Product and Process Development 42
References 44
Chapter 3: New Technologies: From Basic Ideas to Mature Technologies 46
3.1 Basics of Linear Flow Splitting and Bend Splitting 47
3.1.1 Process Principles 48
3.1.2 Technology 51
3.1.3 Process Characteristics 55
3.1.4 Process Qualification 58
3.2 Integrated Process Chains for Sheet Metal Structures 65
3.2.1 Roll Forming 67
3.2.2 Cutting Technologies 71
3.2.3 Welding 91
3.2.4 Deep Drawing 93
3.2.5 Process Control 102
3.3 Product Benefits Through Bifurcations 107
3.3.1 Bifurcation at the Edge of Sheet Metal 107
3.3.2 Bifurcation in the Plane of Sheet Metal 108
References 109
Chapter 4: Manufacturing Induced Properties: Determination, Understanding, and Beneficial Use 113
4.1 Effects of Severe Straining in Integral Sheet Metal Design 114
4.1.1 Strength 121
4.1.2 Subsequent Formability 125
4.1.3 Durability 129
4.1.4 Rolling Contact Fatigue 140
4.2 Processing of Manufacturing-Induced Properties for Product Development 146
4.2.1 Linking Manufacturing-Induced Properties to Functional Product Properties 147
4.2.2 Preparation and Documentation of Process-Integrated Design Guidelines 149
4.3 Benefits: Some Examples 150
4.3.1 Mathematical Optimization of Stringer Sheets 150
4.3.2 Light Crane System 153
References 156
Chapter 5: Finding the Best: Mathematical Optimization Based on Product and Process Requirements 160
5.1 Formalization of the Design Task 162
5.1.1 Modeling of Technical Systems by Properties 163
5.1.2 Requirement Acquisition and Transformation into Properties 167
5.1.3 Integration of Manufacturing Technologies 172
5.1.4 Formalized Integrated Product and Process Design Task 176
5.2 Optimization of Product Design 178
5.2.1 Geometry Optimization of Multi-Chambered Profiles 182
Algorithm 5.1 (SQP with l1-penalty globalization) 183
5.2.2 Topology and Geometry Optimization: A Combined Approach 184
5.2.3 Geometry Optimization of Hydroformed Branched Sheet Metal Products 188
5.2.4 Shape Optimization of Mechanical Connections 190
5.3 Process Optimization 194
5.3.1 Optimal Control of Deep Drawing Processes 194
Algorithm 5.2 (Bundle-ROM-based Trust Region algorithm with Levenberg regularization) 201
5.3.2 Partitioning 202
Algorithm 5.3 (Brute-force algorithm for finding an optimal partition) 205
5.3.3 Production Sequence 206
5.4 Beneficial Effects of Formalization and Optimization 208
References 209
Chapter 6: Computer-Integrated Engineering and Design 214
6.1 Integrated Information Model 217
6.1.1 Core Model 218
6.1.2 Products and Production Processes 221
6.2 CAD Modeling for Bifurcated Sheet Metal Parts 224
6.2.1 Direct Modeling Approach 225
6.2.2 Algorithmic Modeling Approach 231
6.2.3 Panelization of Freeform Building Facades 235
6.3 Process Simulation 237
6.3.1 Linear Flow Splitting Simulation of the Macro Geometry 237
6.3.2 Simulation of Local Properties 242
6.4 Fatigue Strength Simulation 245
6.4.1 Linear Flow Split Structures 245
6.4.2 Deep Drawn Structures 250
References 253
Chapter 7: New Challenges: Technology Integrated Market-Pull 257
7.1 New Processes 258
7.1.1 Integrated Bending 258
7.1.2 Flexible Flow Splitting 261
7.2 New Products of Sheet Metal Panels 272
7.2.1 Panelization of Free-Form Architecture Using Flexible Modules 272
7.2.2 Joints with Flow Split Flanges 276
7.2.3 Multifunctional Building Modules 277
7.3 Implementation of Our Approach on Aesthetical Demands 282
References 285
Chapter 8: Finding New Opportunities: Technology Push Approach 287
8.1 Technology-Pushed Product Innovation 288
8.1.1 From Manufacturing-Induced Properties to Product Innovation 289
8.1.2 Linear Flow Split Linear Guides 291
8.2 Technology-Pushed Process Innovation 298
8.2.1 Process Innovation Driven by Manufacturing-Induced Properties 299
8.2.2 Mechanical Joining by Linear Flow Splitting 302
8.3 Concurrent Technology-Pushed Product and Process Innovation 309
References 310
Chapter 9: The Result: A New Design Paradigm 312
9.1 Integrated Algorithm-Based Product and Process Development 313
9.1.1 The Integrated Approach 313
9.1.2 Impacts of the Integrated Approach 316
9.2 Case Studies 320
9.2.1 Facade Cleaning System 320
9.2.2 Integrated Fastenings for Hangers 331
9.2.3 Nonlinear Skywalk Beam 337
References 345
Index 346