scholarly journals Automating Redesign of Sheet-Metal Parts in Automotive Industry Using KBE and CBR

2006 ◽  
Author(s):  
Marcus Sandberg ◽  
Tobias Larsson
Keyword(s):  
Product Development ◽  
Sheet Metal ◽  
Automotive Industry ◽  
Feature Recognition ◽  
Case Based Reasoning ◽  
Research Issues ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Cad System ◽  
Industrial Implementation

Automating redesign is an approach for engineering designers to prevent design related manufacturability problems in early product development and thus reduce costly design iterations. A vast amount of work exists, with most research findings seemingly staying within the research community rather than finding its way into use in industrial settings where research issues have often evolved from the concerned applied research. The aim of this paper is to present an approach with industrial implementation potential regarding automating redesign of sheet-metal components in early product development to avoid manufacturing problems due to design flaws and non-optimal designs. Geometry, generated by a knowledge-based engineering (KBE) system, gives input to the case-based reasoning (CBR) governed manufacturing planning. If geometry is found non-manufacturable or enhancement of already manufacturable geometry is possible, the CBR system will suggest redesign actions to resolve the problem. CBR extends the capabilities of the rule-based KBE-system by enabling plan-based evaluation. The approach has the potential for industrial implementation, since KBE is often closely coupled to an industrial CAD-system, hence enabling technology is at the industry. Also, combining KBE and CBR reduces the coding effort compared to coding the whole design support with CBR, as feature recognition is simplified by means of KBE. A case study of development of sheet-metal manufactured parts at a Swedish automotive industry partner presents the method in use. As it is shown that redesign can be automated for sheet-metal parts there is a potential for reducing costly design and manufacturing iterations.

A Model for the Representation of Surface Roughness and Form Deviation in Geometry Models

2013 ◽  
Author(s):  
Oliver Weitzmann ◽  
Reiner Anderl
Keyword(s):  
Surface Roughness ◽  
Product Development ◽  
Surface Properties ◽  
Sheet Metal ◽  
Functional Integration ◽  
Higher Order ◽  
Linear Flow ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Flow Splitting

Functional integration and resource utilization are a challenge in today’s product development. The selective utilization of surface properties for functional integration offers potentials which aren’t exhausted until now. Surface roughness is mostly considered in manufacturing and measurement but the product properties impacted by surface roughness are determined in the product development. So it is necessary to integrate and extend the information about surface roughness in the methods and models of the product development. Therefore an approach for the representation of surface properties in product development is evolved. Based on the classification of surface deviation and profile courses, a method for building a surface profile is explored and depicted in an object-oriented representation model. One example for the functional integration and the use of technology-induced properties are sheet metal parts with higher order bifurcation in integral style. A new massive forming technology called linear flow splitting enables the manufacturing of sheet metal parts with higher order bifurcation in integral style. Within this manufacturing process, the material properties change heavily. Considering these changes in the product development, the representation model is needed to ensure the functionality. The model is used for generation a typical surface resulting from a linear flow splitting process.

Feature Recognition and Parameterization Methods for Algorithm-Based Product Development Process

2017 ◽  
Author(s):  
Thiago Weber Martins ◽  
Reiner Anderl
Keyword(s):  
Product Development ◽  
Sheet Metal ◽  
Development Process ◽  
Feature Recognition ◽  
Mathematical Optimization ◽  
Product Development Process ◽  
Sheet Metal Parts ◽  
Cad Models ◽  
Feature Based ◽  
Metal Products

The algorithm-based product development process applies mathematical optimization tools in the conceptual steps of the product development process. It relies on formalized data such as initial loads and boundary conditions to find the best product solution for optimized bifurcated sheet metal parts. Previous research efforts focused on the automation of CAD modeling steps. Current algorithms are able to generate the CAD models of optimized bifurcated sheet metal products automatically, however, they are rough with low-level of detail and abstraction. Consequently, CAD models are embodied and detailed manually in a partly iterative and time-consuming process to include parameters, constraints and design features. Hence, this paper introduces feature recognition and parametrization methods for the algorithm-based product development of bifurcated sheet metal products. It proposes the inclusion of a pre-processor to analyze the solution graph resulted from topology optimization before the generation of CAD models. Algorithms that derive the geometric shape from the solution graph by recognizing features as well as assigning parameters are introduced. Then, feature-based CAD models of bifurcated sheet metal products are automatically generated. The proposed methods and algorithms are implemented with Python and validated with a use-case. Benefits and limitations of the proposed methods are discussed.

FE Simulation of Sheet Metal Forming – State of the Art in Automotive Industry

2005 ◽  
Vol 6-8 ◽  
pp. 13-18 ◽  
Author(s):  
H.J. Haepp ◽  
M. Rohleder
Keyword(s):  
Sheet Metal ◽  
Automotive Industry ◽  
Development Process ◽  
High Strength Steels ◽  
Feasibility Studies ◽  
High Strength ◽  
Element Analysis ◽  
Early Design ◽  
Metal Parts ◽  
Sheet Metal Parts

Nowadays feasibility studies using finite element analysis are performed in very early design phases of sheet metal parts forming. Further, simulation technology is used to optimize the first forming stage. Because of the ever intensifying international competition and the increased use of high-strength steels and aluminum alloys, the absorption of springback deviations is a great challenge, especially in the automotive industry. The application of numerical computation to predict springback deviations and to create compensated die designs in early design phases of sheet metal parts forming becomes essential. At DaimlerChrysler the numerically based compensation of springback deviations during the die development process of complex car parts is achieved. However, developments to optimize and compensate dies automatically or to predict form deviations on assemblies are still necessary.

Web-Based Application for Algorithm Based Product Development Process of Integral Bifurcated Sheet Metal Parts

2016 ◽  
Author(s):  
Thiago Weber Martins ◽  
Christian Steinmetz ◽  
Katharina Albrecht ◽  
Reiner Anderl
Keyword(s):  
Product Development ◽  
Sheet Metal ◽  
Information Exchange ◽  
Development Process ◽  
Heterogeneous Data ◽  
Product Development Process ◽  
Cad Model ◽  
Web Based ◽  
Metal Parts ◽  
Sheet Metal Parts

Within the Collaborative Research Center 666 the algorithm based product development process has been established. It is based on state of the art product development methodologies and enhanced in order to optimize the product development process of integral bifurcated sheet metal parts. Algorithms based on mathematical optimization approaches as well as the initial product requirements and constraints information are applied to obtain an optimized design as CAD-Model. Regarding this methodology there are still some challenges to be solved, such as reduction of iterations steps to elaborate final product design as CAD-model, use of heterogeneous data as well as software and enhancement of information exchange. Therefore, this paper introduces a concept for a web-based application to support the algorithmic product development methodology and CAD modeling in CRC 666. It enables the development and adaptation of integral bifurcated parts based on the initial optimization data provided by XML-files. Besides the description of use cases and use scenarios, the concept is implemented as a web-based application for validation purposes. Based on the validation, advantages and limitations of the presented approach are discussed.

CAD Systems and Cognitive Complexity: Beyond the Drafting Board Metaphor

1991 ◽  
Author(s):  
David Robertson ◽  
Karl T. Ulrich ◽  
Marc Filerman
Keyword(s):  
Sheet Metal ◽  
Cognitive Complexity ◽  
Computer Aided Design ◽  
Product Development Process ◽  
Input Device ◽  
Cad Systems ◽  
Metal Parts ◽  
Sheet Metal Parts ◽  
Cad System ◽  
Engineering Managers

Abstract Computer-Aided Design (CAD) systems can and should support and enhance the product development process. Unfortunately, the benefits delivered by current systems have not met users’ expectations. We believe that CAD systems should be designed to minimize the cognitive complexity facing the engineer; CAD systems should be easy to use and should help the engineer manage design-related complexity. A series of propositions are developed which refine these ideas. To evaluate the central propositions, we constructed a prototype CAD system for the design of blanked and bent sheet metal parts. The user of the system is provided with a hand-held input device which interprets actions of the user’s hands as production operations on a CAD representation of the part. The user creates sheet metal parts by bending, stretching, pushing, and moving the input device. The system was demonstrated to engineers, engineering managers, and researchers, who provided ideas for future enhancements. Reactions to the demonstrations of the system have helped evaluate the concepts behind the system. Although we have used sheet metal as an example domain, we believe these ideas can be applied in other design contexts.

scholarly journals Feature Recognition for Structural Aerospace Sheet Metal Parts

2019 ◽  
Vol 17 (1) ◽  
pp. 16-43
Author(s):  
Seyedmorteza Ghaffarishahri ◽  
Louis Rivest
Keyword(s):  
Sheet Metal ◽  
Feature Recognition ◽  
Metal Parts ◽  
Sheet Metal Parts
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