Recent Achievements in Numerical Simulation in Sheet Metal Forming Processes

Purpose of this paper: During the recent 10-15 years, Computer Aided Process Planning and Die Design evolved as one of the most important engineering tools in sheet metal forming, particularly in the automotive industry. This emerging role is strongly emphasized by the rapid development of Finite Element Modelling, as well. The purpose of this paper is to give a general overview about the recent achievements in this very important field of sheet metal forming and to introduce some special results in this development activity. Design/methodology/approach: Concerning the CAE activities in sheet metal forming, there are two main approaches: one of them may be regarded as knowledge based process planning, whilst the other as simulation based process planning. The author attempts to integrate these two separate developments in knowledge and simulation based approach by linking commercial CAD and FEM systems. Findings: Applying the above approach a more powerful and efficient process planning and die design solution can be achieved radically reducing the time and cost of product development cycle and improving product quality. Research limitations: Due to the different modelling approaches in CAD and FEM systems, the biggest challenge is to enhance the robustness of data exchange capabilities between various systems to provide an even more streamlined information flow. Practical implications: The proposed integrated solutions have great practical importance to improve the global competitiveness of sheet metal forming in the very important segment of industry. Originality/value: The concept described in this paper may have specific value both for process planning and die design engineers

Проектирование электрических силовых установок при поддержке многоцелевыми стратегиями оптимизации

Electric drive systems consisting of battery, inverter, electric motor and gearbox are applied in hybridor purely electric vehicles. The layout process of such propulsion systems is performed on system level under consideration of various component properties and their interfering characteristics. In addition, different boundary conditions are taken under account, e. g. performance, efficiency, packaging, costs. In this way, the development process of the power train involves a broad range of influencing parameters and periphery conditions and thus represents a multi-dimensional optimization problem. Stateof-the-art development processes of mechatronic systems are usually executed according to the V-model, which represents a fundamental basis for handling the complex interactions of the different disciplines involved. In addition, stage-gate processes and spiral models are applied to deal with the high level of complexity during conception, design and testing. Involving a large number of technical and economic factors, these sequential, recursive processes may lead to suboptimal solutions since the system design processes do not sufficiently consider the complex relations between the different, partially conflicting domains. In this context, the present publication introduces an integrated multi-objective optimization strategy for the effective conception of electric propulsion systems, which involves a holistic consideration of all components and requirements in a multi-objective manner. The system design synthesis is based on component-specific Pareto-optimal designs to handle performance, efficiency, package and costs for given system requirements. The results are displayed as Pareto-fronts of electric power train system designs variants, from which decision makers are able to choose the best suitable solution. In this way, the presented system design approach for the development of electrically driven axles enables a multi-objective optimization considering efficiency, performance, costs and package. It is capable to reduce development time and to improve overall system quality at the same time.Системы электропривода, состоящие из аккумулятора, инвертора, электродвигателя и коробки передач, применяются в гибридных или чисто электрических транспортных средствах. Процесс компоновки таких движительных систем осуществляется на системном уровне с учетом различных свойств компонентов и их интерферирующих характеристик. Кроме того, учитываются разные граничные условия, например технические характеристики, эффективность, комплектование, стоимость. Таким образом, процесс разработки силовой передачи включает в себя широкий диапазон влияющих параметров и периферических условий и тем самым представляет собой проблему многомерной оптимизации. Современные процессы разработки мехатронных систем обычно выполняются в соответствии с V-моделью, которая представляет собой фундаментальную основу для управления сложными взаимодействиями различных дисциплин. Кроме того, применяются этапные процессы и спиральные модели, чтобы справиться с высоким уровнем сложности при разработке, проектировании и тестировании. Вовлекая большое количество технических и экономических факторов, эти последовательные рекурсивные процессы могут привести к неоптимальным решениям, поскольку процессы проектирования системы недостаточно учитывают сложные отношения между различными, частично конфликтующими областями. В этом контексте настоящая публикация представляет интегрированную многоцелевую стратегию оптимизации для эффективной концепции электрических силовых установок, включающую комплексное рассмотрение всех компонентов и требований на многоцелевой основе. Синтез системного дизайна основан на Парето-оптимальных конструкциях со специфическими компонентами с целью обеспечения работы, эффективности, комплектации и затрат, предусмотренных для данной системы. Результаты отображаются в виде Парето-фронтов вариантов систем электрических трансмиссий, из которых лица, принимающие решения, могут выбрать наиболее подходящее из них. Таким образом, представленный подход к проектированию системы для разработки осей с электрическим приводом обеспечивает многоцелевую оптимизацию с учетом эффективности, функционирования, стоимости и комплектации. Данный подход позволяет сократить время разработки и одновременно обеспечить улучшение качества системы

Intelligent support to specific design aspects

Due to increased rivalry on the market, some specific design aspects like the use of modern plastics materials, ergonomics and aesthetics are becoming more important and are not kept in the background any more in correlation with functionality and economic aspect of the product. Design engineer faces many dilemmas while designing new products as a single person is not able to possess a wide spectrum of knowledge needed for optimal design solutions. At this point designer have to rely on his or her experience and on the knowledge of the expert team involved in the project. The fundamental purpose of the research presented in this paper is to make the product development process less experience dependent. The main goal of thematically oriented research is to develop intelligent advisory system with integrated modules forsome specific design aspects

An exploration of materials and methods in manufacturing : shoreline membranes

Thesis (M.Arch.)--Massachusetts Institute of Technology, Dept. of Architecture, 2000.Includes bibliographical references (p. 87-88).This thesis is an investigation into the design methodologies and ideologies of manufacturing processes specifically related to automotive design. The conceptualization, prototyping, testing, and manufacturing of cars is a discipline that would yield exciting results if applied to architecture. The hybridization of different processes of design will raise interesting questions of how built form is conceived, designed, developed, and constructed. An essential part of this thesis research is the study of materials. After an intense investigation of the potential uses and intrinsic properties of new materials in the automotive and construction industries, a select few materials will be applied directly in the thesis. The final component of the thesis is a programmatic theme that will revolve around shoreline membranes. They provide a lightweight and flexible system of architecture for many different building types. The investigation will involve the design of a structure in which its conception, function, production, and form are the direct result of inspiration from automotive manufacturing techniques and material research.by Ryan C.C. Chin.M.Arch

Parametric Design, Modeling, and Optical Evaluation of Retroreflective Prismatic Structures

Retroreflectors (RR) are defined as passive optical structures that redirect incident light to its originating source. Specific types of retroreflectors called inverted cubes (ICs) function through total internal reflection (TIR) and are used in various applications such as measurement tools, traffic signs and automotive rear and side lighting. This thesis aims to model, analyze, fabricate and study a novel type of IC retroreflectors called right triangular prism (RTP). A parametric approach is used to model existing IC geometries from a generic unit cube and is then implemented to model the novel RTP geometry. Those elements are then tested by optical simulation software in single element and areal forms and their performances are compared. Moreover, fabricated prototype arrays of RTPs were separately tested using a digital lux meter and a luminance imaging system. Both virtual and physical optical experimentation proved that the newly designed RTP structure is indeed functional and have the potential to be used in many applications

Challenges for CAx and EDM in an international automotive company

In design and manufacturing of passenger cars, changes in processes and tools pose new challenges for the management of engineering data. In this paper, the status quo, challenges, and developments are elaborated using the example of a globally operating automobile manufacturer. Special attention is given to the complexity and variance of the products, to paradigm shifts in design philosophies, to trends targeting the IT environment, and to user bias. Finally, conclusions are drawn for future CAx and EDM1 concepts and strategies

Industrial Design Structure: a straightforward organizational integration of DFSS and QFD in a new industry and market reality

Purpose: The aim of this research is to enlighten the methodology model of Industrial Design Structure (IDeS) that integrates the internal and external customer feedback embodied both in methods of quality function deployment (QFD) and as basis of design for six sigma (DFSS) steps to systematically bring the information across the entire organization, saving overall product development time and resources. Design/methodology/approach: The paper describes the state of the art enlightened to establish the disadvantages and challenges of other methods taken into consideration in the study like QFD and DFSS that, together with the need of companies to react fast to changes they need to straightforwardly implement product development information across all departments, leading to a mass customization infrastructure. Several application trials of this methodology have been cited. Findings: The IDeS method has established to been able to integrate other well-known methodologies to gather technical specifications starting from voice of customers (VOCs) like QFD that served to canalize the generalist approach of define, measure, analyze, design and verify (DMADV) of DFSS in order to reach into a larger share of the organization and englobe by following the overall product design steps of an industrial project. Research limitations/implications: The research approach chosen for this document presents the concept of a methodology ought to operate most internal branches in a company driven by product design requirements and guidelines. Therefore, researchers are encouraged to develop further studies on the IDeS method are required in order to adapt this methodology to specific management tools that would help to ease information gathering for immediate analysis and modification. Practical implications: The paper implicates that a need to interchange information systematically across all subdivisions in the organization, as brisk response to VOC reactions is needed to thrive in the market nowadays, leading to a fast product customization scene. However, the industry is heading into adopting an individual customer-centered product conceptualization ought to be driven by design as a key for individualizing an object. Afterward by taking this concept broadly and adopting it would lead to implement a company organization that would be directly affected by the customer's input. Social implications: The methodology described aims to enable organizations to portray fast and accurate product prototyping, by exploiting technologies from Industry 4.0. Originality/value: This concept proposes a method to canalize the implementation of DFSS by using the DMADV approach, whilst assessing the challenges of adaptation and keeping up with cultural pace that impacts the behavior of buying and consumption and moreover implementing a seamless communication within all departments in the organization to share the development progress and change requests by using similar information technology tools. This would imply important savings in resources, whilst delivering quality products to the society

Automotive styling: Supporting engineering-styling convergence through surface-centric knowledge based engineering

The emotional impression a car imprints on a potential buyer is as equally important for its commercial success as fulfilling functional requirements. Hence, to create a positive emotional impression of a vehicle, great effort is put into a car's styling process. One of the key aspects during the early stages of the automotive design process is the convergence of styling and engineering design. While requirements stemming from engineering design are usually characterised by quantitative values, styling requirements are rather qualitative in nature. Converging these two requirement types is laborious. The present publication focuses on supporting this process through Knowledge Based Engineering. This is achieved by introducing a method which enables the designer to intuitively regard functional requirements during the styling phase. Moreover, the method improves the process of technical requirement checks regarding the shape and orientation of styling surfaces which exceed conventional package verifications

Development of a 1:1 Scale True Perception Virtual Reality System for design review in automotive industry

The recent improvements of Virtual Reality (VR) technologies makes it feasible for automotive design reviews to be carried out in a virtual world. Design review with virtual prototypes could reduce costs by eliminating the need to build physical prototypes, help speed up the design process, and enable the simultaneous examination of different design options. However, the most important challenge to address is whether a true 1:1 scale representation of the vehicle can be achieved in VR; whilst such claims are frequently made, how this is achieved is not reported in the research literature. In this study, a VR system with 1:1 scale true perspective display was created and calibrated using a large stereoscopic screen and optical tracking system. Various vehicle models of differing fidelity were used to test the capability of the system and ideal sizes of model identified. This paper also reports the use of several virtual tools for the design review process, which augment the immersive experience of the observe