Integration of manufacturing-induced properties in product design

doi:10.1016/j.cirp.2012.03.041

CIRP Annals

Volume 61, Issue 1, 2012, Pages 163-166

https://doi.org/10.1016/j.cirp.2012.03.041 Get rights and content

Abstract

Guidelines of the design for manufacturability (DfM) hardly regard neither specific positive effects nor additional functional convenience achievable by specific manufacturing technologies. Consequently, opportunities for design quality improvements are wasted. The paper introduces a new approach in terms of connecting methods of product design, mathematical optimization, process planning and forming technologies, which inherently change material properties of the workpiece. By providing manufacturing-induced properties at an early stage of product design additional functionality can be generated and product complexity reduced. Due to the algorithmic approach design solutions based on different manufacturing technologies can be efficiently compared in mature development stages.

Introduction

New products have to be innovative, aligned to customer needs and stand out from competitive products. Additionally, a distinctive cost advantage is requested. One possibility to approach this challenge is to incorporate characteristic advantages and potentials of the used manufacturing technologies into the product design. Thus, functional benefits that upgrade a new product can be achieved. Furthermore, part complexity can be reduced.

In order to take advantage of the full technological potentials applicable product development methods are necessary. A new approach is described in this paper. It includes methods of discrete and nonlinear optimization and exploits these potentials by integrating the systematic utilization of manufacturing-induced properties into product design. The application is shown for the case of forming technologies. In this group of manufacturing technologies properties of workpieces are extensively affected by plastic deformation and tribological phenomena.

Section snippets

Potentials in given product development processes

The early phases of the product development (PD) process, especially clarification of the task and conceptual design, are essential for the efficiency of the development process and the level of product innovation. Important decisions are made which substantially influence the functionality, costs and quality of the product. Approved approaches like VDI 2221 [1] and VDI 2222 [2] recommend a stepwise, iterative procedure and result in intensive early phases of the PD-process [3] as a basis for

New algorithm based approach

The newly proposed PD-approach is shown in Fig. 1(b). After the clarification of the task and the listing of requirements appropriate manufacturing technologies can be identified. This identification of fitting technologies is based on existing knowledge about manufacturing technologies and their characteristic manufacturing-induced properties.

Since the following design process has to be carried out for every single fitting manufacturing technology a straightforward and efficient design process

Case study: development of a multi-functional linear guide

A linear guide made of steel in a robust design with a minimized number of components is sought after. Besides high stiffness the rail has to offer the functions of clamping the guide slide and detecting its position discretely. Small energy consumption for the linear movement is demanded.

Summary

By incorporating the positive aspects coming from the manufacturing, e.g. forming process into the product development process additional functionality of components can be generated and product complexity can be reduced. This is reached by choosing an appropriate manufacturing technology after having clarified the development task. Hereby the manufacturing-induced properties can systematically be integrated into the design process in order to generate additional functional benefit. Furthermore

Acknowledgements

The investigations presented in this paper were carried out within the research projects A1, A2, A3, B1, B4 and D1 of the Collaborative Research Centre 666 ‘Integral sheet metal design with higher order bifurcations—Development, Production, Evaluation’. The authors thank the German Research Foundation (DFG) for founding and supporting the CRC 666.

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Integration of manufacturing-induced properties in product design

Abstract

Introduction

Section snippets

Potentials in given product development processes

New algorithm based approach

Case study: development of a multi-functional linear guide

Summary

Acknowledgements

Journal of Materials Processing Technology

Journal of Materials Processing Technology

Tribology International

Journal of Materials Processing Technology

Journal of Materials Processing Technology

Annals of the CIRP

Annals of the CIRP

Annals of the CIRP

Journal of Materials Processing Technology

Systematic Approach to the Development and Design of Technical Systems and Products

Part 1. Methodic Development of Solution Principles