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Table of Contents
Preface; Contents; Contributors; Abbreviations; Symbols; Chapter 1: Introduction: Production Technologies and Product Development; 1.1 The Interaction Between Product Development and Production Technology; 1.2 Incorporation of Production in Current Product Development Approaches; 1.3 Market Pull vs. Technology Push; References; Chapter 2: The CRC666 Approach: Realizing Optimized Solutions Based on Production Technological Innovation; 2.1 Motivation for and Goals of a New Development Approach; 2.2 Options in Manufacturing Technologies; 2.3 Manufacturing-Induced Properties
2.4 Mathematical Optimization of Product Geometries and Manufacturing Processes2.4.1 Classification of Optimization Tasks; 2.4.2 Examples for Optimization; 2.5 Integrated Algorithm-Based Product and Process Development; References; Chapter 3: New Technologies: From Basic Ideas to Mature Technologies; 3.1 Basics of Linear Flow Splitting and Bend Splitting; 3.1.1 Process Principles; 3.1.2 Technology; 3.1.3 Process Characteristics; 3.1.4 Process Qualification; 3.2 Integrated Process Chains for Sheet Metal Structures; 3.2.1 Roll Forming; 3.2.2 Cutting Technologies; 3.2.3 Welding
3.2.4 Deep Drawing3.2.5 Process Control; 3.3 Product Benefits Through Bifurcations; 3.3.1 Bifurcation at the Edge of Sheet Metal; 3.3.2 Bifurcation in the Plane of Sheet Metal; References; Chapter 4: Manufacturing Induced Properties: Determination, Understanding, and Beneficial Use; 4.1 Effects of Severe Straining in Integral Sheet Metal Design; 4.1.1 Strength; 4.1.2 Subsequent Formability; 4.1.3 Durability; 4.1.4 Rolling Contact Fatigue; 4.2 Processing of Manufacturing-Induced Properties for Product Development; 4.2.1 Linking Manufacturing-Induced Properties to Functional Product Properties
4.2.2 Preparation and Documentation of Process-Integrated Design Guidelines4.3 Benefits: Some Examples; 4.3.1 Mathematical Optimization of Stringer Sheets; 4.3.2 Light Crane System; References; Chapter 5: Finding the Best: Mathematical Optimization Based on Product and Process Requirements; 5.1 Formalization of the Design Task; 5.1.1 Modeling of Technical Systems by Properties; 5.1.2 Requirement Acquisition and Transformation into Properties; 5.1.3 Integration of Manufacturing Technologies; 5.1.4 Formalized Integrated Product and Process Design Task; 5.2 Optimization of Product Design
5.2.1 Geometry Optimization of Multi-Chambered ProfilesAlgorithm 5.1 (SQP with l1-penalty globalization); 5.2.2 Topology and Geometry Optimization: A Combined Approach; 5.2.3 Geometry Optimization of Hydroformed Branched Sheet Metal Products; 5.2.4 Shape Optimization of Mechanical Connections; 5.3 Process Optimization; 5.3.1 Optimal Control of Deep Drawing Processes; Algorithm 5.2 (Bundle-ROM-based Trust Region algorithm with Levenberg regularization); 5.3.2 Partitioning; Algorithm 5.3 (Brute-force algorithm for finding an optimal partition); 5.3.3 Production Sequence
2.4 Mathematical Optimization of Product Geometries and Manufacturing Processes2.4.1 Classification of Optimization Tasks; 2.4.2 Examples for Optimization; 2.5 Integrated Algorithm-Based Product and Process Development; References; Chapter 3: New Technologies: From Basic Ideas to Mature Technologies; 3.1 Basics of Linear Flow Splitting and Bend Splitting; 3.1.1 Process Principles; 3.1.2 Technology; 3.1.3 Process Characteristics; 3.1.4 Process Qualification; 3.2 Integrated Process Chains for Sheet Metal Structures; 3.2.1 Roll Forming; 3.2.2 Cutting Technologies; 3.2.3 Welding
3.2.4 Deep Drawing3.2.5 Process Control; 3.3 Product Benefits Through Bifurcations; 3.3.1 Bifurcation at the Edge of Sheet Metal; 3.3.2 Bifurcation in the Plane of Sheet Metal; References; Chapter 4: Manufacturing Induced Properties: Determination, Understanding, and Beneficial Use; 4.1 Effects of Severe Straining in Integral Sheet Metal Design; 4.1.1 Strength; 4.1.2 Subsequent Formability; 4.1.3 Durability; 4.1.4 Rolling Contact Fatigue; 4.2 Processing of Manufacturing-Induced Properties for Product Development; 4.2.1 Linking Manufacturing-Induced Properties to Functional Product Properties
4.2.2 Preparation and Documentation of Process-Integrated Design Guidelines4.3 Benefits: Some Examples; 4.3.1 Mathematical Optimization of Stringer Sheets; 4.3.2 Light Crane System; References; Chapter 5: Finding the Best: Mathematical Optimization Based on Product and Process Requirements; 5.1 Formalization of the Design Task; 5.1.1 Modeling of Technical Systems by Properties; 5.1.2 Requirement Acquisition and Transformation into Properties; 5.1.3 Integration of Manufacturing Technologies; 5.1.4 Formalized Integrated Product and Process Design Task; 5.2 Optimization of Product Design
5.2.1 Geometry Optimization of Multi-Chambered ProfilesAlgorithm 5.1 (SQP with l1-penalty globalization); 5.2.2 Topology and Geometry Optimization: A Combined Approach; 5.2.3 Geometry Optimization of Hydroformed Branched Sheet Metal Products; 5.2.4 Shape Optimization of Mechanical Connections; 5.3 Process Optimization; 5.3.1 Optimal Control of Deep Drawing Processes; Algorithm 5.2 (Bundle-ROM-based Trust Region algorithm with Levenberg regularization); 5.3.2 Partitioning; Algorithm 5.3 (Brute-force algorithm for finding an optimal partition); 5.3.3 Production Sequence