Integrated computational product and production engineering for multi-material lightweight structures
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ORIGINAL ARTICLE
Integrated computational product and production engineering for multi-material lightweight structures 1 · Antal Der ´ 1 · Sebastian Gellrich1 · Tim Ossowski1 · Ralf Lorenz2 · Bernd-Arno Behrens2 · ¨ Andre´ Hurkamp 1 1 · Sebastian Thiede1 ¨ Christoph Herrmann · Klaus Droder
Received: 12 March 2020 / Accepted: 9 August 2020 © The Author(s) 2020
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 Product development · Production engineering · Multi-scale simulation · Machine learning · Multi-material lightweight structures
1 Introduction In today’s product development, virtual tools are used more frequently, leading to a reduction of physical prototypes and experimental testing. Virtual testing leads to a reduction of the development time, to cost savings, and to an increase in quality due to the fast evaluation of different designs [1]. A development without physical prototypes can therefore contribute to an improvement in the economic and environmental efficiency of product development processes. Especially potential environmental impacts can hardly be Andr´e H¨urkamp
[email protected] 1
Institute of Machine Tools and Production Technology, Technische Universit¨at Braunschweig, Langer Kamp 19b, 38106 Braunschweig, Germany
2
Institute of Forming Technology and Machines, Leibniz Universit¨at Hannover, An der Universit¨at 2, 30823 Garbsen, Germany
tested by physical prototypes. Virtual methods, which make it possible to determine the environmental impac
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