Integration of cutting time into the structural optimization process: application to a spreader bar design

Nowadays, there is no doubt about the suitability and efficiency of structural optimization techniques and the improvement achieved in the design process when they are applied. However, if we look to the product design process, do we really believe that it is an unbeatable improvement? Current structural optimization methods (based on metrics such as stress, mass or compliance) have reached a high level of development, but their integration with other factors as manufacturing processes is still at an early stage of development. In many cases, those designs suggested applying only structural optimization are found to be difficult and/or expensive to manufacture. This situation is further accentuated in the case of cutting processes, where it is well-known that structural optimization significantly affects to the cutting time and commonly produces manufacturing overcost. In this sense, this paper tries to fill the gap between structural optimization and manufacturing-based design applied to the case of cutting processes. For this purpose, the authors propose a methodology that allows including those parameters that affect to the cutting time within structural optimization phase. Additionally, to obtain a fair conclusion about its performance the method is applied to a real industrial component manufactured by a cutting process as it is the Abrasive Waterjet Cutting (AWJ).