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

authored by: André Hürkamp, Antal Dér, Sebastian Gellrich, Tim Ossowski, Ralf Lorenz, Bernd Arno Behrens, Christoph Herrmann, Klaus Dröder, Sebastian Thiede
Abstract: 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.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
External Organisation(s): Technische Universität Braunschweig
Type: Article
Journal: International Journal of Advanced Manufacturing Technology
Volume: 110
Pages: 2551-2571
No. of pages: 21
ISSN: 0268-3768
Publication date: 10.2020
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Control and Systems Engineering, Software, Mechanical Engineering, Computer Science Applications, Industrial and Manufacturing Engineering
Electronic version(s): https://doi.org/10.1007/s00170-020-05895-6 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{5fdee938fe0941ac85f47f3e1fd8986d,
title = "Integrated computational product and production engineering for multi-material lightweight structures",
abstract = "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.",
keywords = "Machine learning, Multi-material lightweight structures, Multi-scale simulation, Product development, Production engineering",
author = "Andr{\'e} H{\"u}rkamp and Antal D{\'e}r and Sebastian Gellrich and Tim Ossowski and Ralf Lorenz and Behrens, {Bernd Arno} and Christoph Herrmann and Klaus Dr{\"o}der and Sebastian Thiede",
note = "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. ",
year = "2020",
month = oct,
doi = "10.1007/s00170-020-05895-6",
language = "English",
volume = "110",
pages = "2551--2571",
journal = "International Journal of Advanced Manufacturing Technology",
issn = "0268-3768",
publisher = "Springer London",
number = "9-10",
}