Manufacturing Integrated Design

1 Introduction: Production Technologies and Product Development1.1 The Interaction between Product Development and Production Technologies1.2 Incorporation of Production in Current Product Development Approaches1.3 Market Pull vs. Technology Push 2 The CRC666 Approach: Realizing Optimized Solutions Based on Production Technological Innovation2.1 Motivation for and Goals of a New Development Approach2.2 Options in Manufacturing Technologies2.3 Manufacturing-induced Properties2.4 Mathematical Optimization of Product Geometries and Manufacturing Processes2.5 Integrated Algorithm-based Product and Process Development 3 New Technologies: From Basic Ideas to Mature Technologies3.1 Basics of Linear Flow Splitting and Bend Splitting3.1.1 Process Principles3.1.2 Technology3.1.3 Process Characteristics3.1.4 Process Qualification3.2 Integrated Process Chains for Sheet Metal Structures3.2.1 Roll Forming3.2.2 Cutting Technologies3.2.3 Welding3.2.4 Deep Drawing3.2.5 Process Control3.3 Product Benefits Through Bifurcations3.3.1 Bifurcation at the Edge of Sheet Metal3.3.2 Bifurcation in the Plane of Sheet Metal 4 Manufacturing-induced Properties: Determination, Understanding and Beneficial Use4.1 Effects of Severe Straining in Integral Sheet Metal Design4.1.1 Strength4.1.2 Subsequent Formability4.1.3 Durability4.1.4 Rolling Contact Fatigue4.2 Processing of Manufacturing-induced Properties for Product Development4.2.1 Linking Manufacturing-induced Properties to Functional Product Properties4.2.2 Preparation and Documentation of Process Integrated Design Guidelinesenefits - Some Examples4.3.1 Mathematical Optimization of Stringer Sheets 4.3.2 Light Crane System 5 Finding the Best: Mathematical Optimization Based on Product and Process Requirements5.1 Formalization of the Design Task5.1.1 Modeling of Technical Systems by Properties5.1.2 Requirement Acquisition and Transformation into Properties5.1.3 Integration of Manufacturing Technologies5.1.4 Formalized Integrated Product and Process Design Task5.2 Optimization of Product Design5.2.1 Geometry Optimization of Multi-chambered Profiles5.2.2 Topology and Geometry Optimization: A Combined Approach5.2.3 Geometry Optimization of Hydroformed Branched Sheet Metal Products5.2.4 Shape Optimization of Mechanical Connections5.3 Process Optimization5.3.1 Optimal Control of Deep Drawing Processes5.3.2 Partitioning5.3.3 Production Sequence5.4 Beneficial Effects of Formalization and Optimization 6 Computer Integrated Engineering and Design6.1 Integrated Information Model6.1.1 Core Model6.1.2 Products and Production Processes6.2 CAD Modeling for Bifurcated Sheet Metal Parts6.2.1 Direct Modeling Approach6.2.2 Algorithmic Modeling Approach6.2.3 Panelization of Freeform Building Facades6.3 Process Simulation 6.3.1 Linear Flow Splitting Simulation of the Macro Geometry6.3.2 Simulation of Local Properties6.4 Fatigue Strength Simulation6.4.1 Linear Flow Split Structures6.4.2 Deep Drawn Structures 7 New Challenges: Technology Integrated Market-Pull7.1 New Processes7.1.1 Integrated Bending7.1.2 Flexible Flow Splitting7.2 New Products of Sheet Metal Panels7.2.1 Panelization of Free-form Architecture Using Flexible Modules7.2.2 Joints with Flow Split Flanges7.2.3 Multifunctional Building Modules7.3 Implementation of our Approach on Aesthetical Demands 8 Finding New Opportunities: Technology Push Approach8.1 Technology-pushed Product Innovation8.1.1 From Manufacturing-induced Properties to Product Innovation8.1.2 Linear Flow Split Linear Guides8.2 Technology-pushed Process Innovation8.2.1 Process Innovation Driven by Manufacturing-induced Properties8.2.2 Mechanical Joining by Linear Flow Splitting8.3 Concurrent Technology-pushed Product and Process Innovation 9 The Result: A New Design Paradigm9.1 Integrated Algorithm-based Product and Process Development9.1.1 The Integrated Approach9.1.2 Impacts of the Integrated Approach9.2 Case Studies9.2.1 Facade Cleaning System9.2.2 Integrated Fastenings for Hangers9.2.3 Nonlinear Skywalk Beam