Integration of manufacturing-induced properties in product design
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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