Manufacturing Integrated Design Sheet Metal Product and Process Innovation 1st Edition by Peter Groche, Enrico Bruder, Sebastian Gramlich 3319523774 9783319523774

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Product details:

ISBN-10 :  3319523774 

ISBN-13 : 9783319523774

Author:  Peter Groche, Enrico Bruder, Sebastian Gramlich

The book gives a systematic and detailed description of a new integrated product and process development approach for sheet metal manufacturing. Special attention is given to manufacturing that unites multidisciplinary competences of product design, material science, and production engineering, as well as mathematical optimization and computer based information technology. The case study of integral sheet metal structures is used by the authors to introduce the results related to the recent manufacturing technologies of linear flow splitting, bend splitting, and corresponding integrated process chains for sheet metal structures.

Manufacturing Integrated Design Sheet Metal Product and Process Innovation 1st Table of contents:

Chapter 1: Introduction: Production Technologies and Product Development
1.1 The Interaction Between Product Development and Production Technology
1.2 Incorporation of Production in Current Product Development Approaches
1.3 Market Pull vs. Technology Push
References
Chapter 2: The CRC666 Approach: Realizing Optimized Solutions Based on Production Technological Inno
2.1 Motivation for and Goals of a New Development Approach
2.2 Options in Manufacturing Technologies
2.3 Manufacturing-Induced Properties
2.4 Mathematical Optimization of Product Geometries and Manufacturing Processes
2.4.1 Classification of Optimization Tasks
2.4.2 Examples for Optimization
2.5 Integrated Algorithm-Based Product and Process Development
References
Chapter 3: New Technologies: From Basic Ideas to Mature Technologies
3.1 Basics of Linear Flow Splitting and Bend Splitting
3.1.1 Process Principles
3.1.2 Technology
3.1.3 Process Characteristics
3.1.4 Process Qualification
3.2 Integrated Process Chains for Sheet Metal Structures
3.2.1 Roll Forming
3.2.2 Cutting Technologies
3.2.3 Welding
3.2.4 Deep Drawing
3.2.5 Process Control
3.3 Product Benefits Through Bifurcations
3.3.1 Bifurcation at the Edge of Sheet Metal
3.3.2 Bifurcation in the Plane of Sheet Metal
References
Chapter 4: Manufacturing Induced Properties: Determination, Understanding, and Beneficial Use
4.1 Effects of Severe Straining in Integral Sheet Metal Design
4.1.1 Strength
4.1.2 Subsequent Formability
4.1.3 Durability
4.1.4 Rolling Contact Fatigue
4.2 Processing of Manufacturing-Induced Properties for Product Development
4.2.1 Linking Manufacturing-Induced Properties to Functional Product Properties
4.2.2 Preparation and Documentation of Process-Integrated Design Guidelines
4.3 Benefits: Some Examples
4.3.1 Mathematical Optimization of Stringer Sheets
4.3.2 Light Crane System
References
Chapter 5: Finding the Best: Mathematical Optimization Based on Product and Process Requirements
5.1 Formalization of the Design Task
5.1.1 Modeling of Technical Systems by Properties
5.1.2 Requirement Acquisition and Transformation into Properties
5.1.3 Integration of Manufacturing Technologies
5.1.4 Formalized Integrated Product and Process Design Task
5.2 Optimization of Product Design
5.2.1 Geometry Optimization of Multi-Chambered Profiles
Algorithm 5.1 (SQP with l1-penalty globalization)
5.2.2 Topology and Geometry Optimization: A Combined Approach
5.2.3 Geometry Optimization of Hydroformed Branched Sheet Metal Products
5.2.4 Shape Optimization of Mechanical Connections
5.3 Process Optimization
5.3.1 Optimal Control of Deep Drawing Processes
Algorithm 5.2 (Bundle-ROM-based Trust Region algorithm with Levenberg regularization)
5.3.2 Partitioning
Algorithm 5.3 (Brute-force algorithm for finding an optimal partition)
5.3.3 Production Sequence
5.4 Beneficial Effects of Formalization and Optimization
References
Chapter 6: Computer-Integrated Engineering and Design
6.1 Integrated Information Model
6.1.1 Core Model
6.1.2 Products and Production Processes
6.2 CAD Modeling for Bifurcated Sheet Metal Parts
6.2.1 Direct Modeling Approach
6.2.2 Algorithmic Modeling Approach
6.2.3 Panelization of Freeform Building Facades
6.3 Process Simulation
6.3.1 Linear Flow Splitting Simulation of the Macro Geometry
6.3.2 Simulation of Local Properties
6.4 Fatigue Strength Simulation
6.4.1 Linear Flow Split Structures
6.4.2 Deep Drawn Structures
References
Chapter 7: New Challenges: Technology Integrated Market-Pull
7.1 New Processes
7.1.1 Integrated Bending
7.1.2 Flexible Flow Splitting
7.2 New Products of Sheet Metal Panels
7.2.1 Panelization of Free-Form Architecture Using Flexible Modules
7.2.2 Joints with Flow Split Flanges
7.2.3 Multifunctional Building Modules
7.3 Implementation of Our Approach on Aesthetical Demands
References
Chapter 8: Finding New Opportunities: Technology Push Approach
8.1 Technology-Pushed Product Innovation
8.1.1 From Manufacturing-Induced Properties to Product Innovation
8.1.2 Linear Flow Split Linear Guides
8.2 Technology-Pushed Process Innovation
8.2.1 Process Innovation Driven by Manufacturing-Induced Properties
8.2.2 Mechanical Joining by Linear Flow Splitting
8.3 Concurrent Technology-Pushed Product and Process Innovation
References
Chapter 9: The Result: A New Design Paradigm
9.1 Integrated Algorithm-Based Product and Process Development
9.1.1 The Integrated Approach
9.1.2 Impacts of the Integrated Approach
9.2 Case Studies
9.2.1 Facade Cleaning System
9.2.2 Integrated Fastenings for Hangers
9.2.3 Nonlinear Skywalk Beam

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Tags: Manufacturing Integrated, Design, Metal Product, Process Innovation, Peter Groche, Enrico Bruder, Sebastian Gramlich