TY - JOUR

T1 - Integrated computational product and production engineering for multi-material lightweight structures

AU - Hürkamp, André

AU - Dér, Antal

AU - Gellrich, Sebastian

AU - Ossowski, Tim

AU - Lorenz, Ralf

AU - Behrens, Bernd Arno

AU - Herrmann, Christoph

AU - Dröder, Klaus

AU - Thiede, Sebastian

N1 - Funding Information: This research and results published are based on the research program Mobilise funded by the Ministry of Science and Culture of Lower Saxony and the Volkswagen Foundation.

PY - 2020/10

Y1 - 2020/10

N2 - Within product development processes, computational models are used with increasing frequency. However, the use of those methods is often restricted to the area of focus, where product design, manufacturing process, and process chain simulations are regarded independently. In the use case of multi-material lightweight structures, the desired products have to meet several requirements regarding structural performance, weight, costs, and environment. Hence, manufacturing-related effects on the product as well as on costs and environment have to be considered in very early phases of the product development process in order to provide a computational concept that supports concurrent engineering. In this contribution, we present an integrated computational concept that includes product engineering and production engineering. In a multi-scale framework, it combines detailed finite element analyses of products and their related production process with process chain and factory simulations. Including surrogate models based on machine learning, a fast evaluation of production impacts and requirements can be realized. The proposed integrated computational product and production engineering concept is demonstrated in a use case study on the manufacturing of a multi-material structure. Within this study, a sheet metal forming process in combination with an injection molding process of short fiber reinforced plastics is investigated. Different sets of process parameters are evaluated virtually in terms of resulting structural properties, cycle times, and environmental impacts.

AB - Within product development processes, computational models are used with increasing frequency. However, the use of those methods is often restricted to the area of focus, where product design, manufacturing process, and process chain simulations are regarded independently. In the use case of multi-material lightweight structures, the desired products have to meet several requirements regarding structural performance, weight, costs, and environment. Hence, manufacturing-related effects on the product as well as on costs and environment have to be considered in very early phases of the product development process in order to provide a computational concept that supports concurrent engineering. In this contribution, we present an integrated computational concept that includes product engineering and production engineering. In a multi-scale framework, it combines detailed finite element analyses of products and their related production process with process chain and factory simulations. Including surrogate models based on machine learning, a fast evaluation of production impacts and requirements can be realized. The proposed integrated computational product and production engineering concept is demonstrated in a use case study on the manufacturing of a multi-material structure. Within this study, a sheet metal forming process in combination with an injection molding process of short fiber reinforced plastics is investigated. Different sets of process parameters are evaluated virtually in terms of resulting structural properties, cycle times, and environmental impacts.

KW - Machine learning

KW - Multi-material lightweight structures

KW - Multi-scale simulation

KW - Product development

KW - Production engineering

UR - http://www.scopus.com/inward/record.url?scp=85091286965&partnerID=8YFLogxK

U2 - 10.1007/s00170-020-05895-6

DO - 10.1007/s00170-020-05895-6

M3 - Article

AN - SCOPUS:85091286965

VL - 110

SP - 2551

EP - 2571

JO - International Journal of Advanced Manufacturing Technology

JF - International Journal of Advanced Manufacturing Technology

SN - 0268-3768

IS - 9-10

ER -