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Early design stage selection of best manufacturing process
Journal of Engineering Design ( IF 2.7 ) Pub Date : 2019-09-18 , DOI: 10.1080/09544828.2019.1662894
Douglas C. Eddy 1 , Sundar Krishnamurty 1 , Ian R. Grosse 1 , Mark Steudel 2
Affiliation  

ABSTRACT Design for additive manufacturing (DFAM) calls for more complex designs to best utilise unique design freedoms to improve designs. Conversely, less complex designs are generally more suitable for conventional manufacturing processes due to the higher cost to produce features that are more complex. As additive manufacturing (AM) emerges as an increasingly viable option to produce products beyond initial prototyping, the choice of conventional versus additive manufacturing must occur as early as possible in the design process as this choice can substantially affect how the product is designed. Realising the right decision too late in a design process will lead to wasted design time, increased time to market the product, a functionally inferior design, and/or a costlier product. To address this critical decision, we introduce a Design for any X Manufacturing (DFXM) method to use at early design stages to identify the best process for a given product design in cases where comprehensive current process databases may not yet be available to a designer to screen process choices. This DFXM method customises targeted questions to break down concepts into the key elements while capturing any known disparate process choices within consistent formulations. The method relates any measurable metrics found for any criteria at conceptual design within these formulations to evaluate them accordingly. A technique is introduced to simplify and focus voluminous process capability information toward that needed for this specialised early stage decision. After initial inputs from a designer, an algorithm automatically computes the best process choice as a function of expected order quantity. Three illustrative case studies demonstrate the practical application of this DFXM method in representative design scenarios.

中文翻译:

最佳制造工艺的早期设计阶段选择

摘要 增材制造 (DFAM) 设计需要更复杂的设计,以最好地利用独特的设计自由来改进设计。相反,不太复杂的设计通常更适合传统的制造工艺,因为生产更复杂的特征的成本更高。随着增材制造 (AM) 成为生产超出初始原型的产品的一种越来越可行的选择,必须在设计过程中尽早选择传统制造与增材制造,因为这种选择会极大地影响产品的设计方式。在设计过程中太晚意识到正确的决定将导致浪费设计时间、增加产品上市时间、功能较差的设计和/或更昂贵的产品。为了应对这一关键决定,我们引入了一种适用于任何 X 制造的设计 (DFXM) 方法,用于在早期设计阶段确定给定产品设计的最佳工艺,以防设计人员可能无法使用全面的当前工艺数据库来筛选工艺选择。这种 DFXM 方法定制了有针对性的问题,将概念分解为关键元素,同时在一致的公式中捕获任何已知的不同过程选择。该方法将在这些公式中为概念设计中的任何标准找到的任何可测量指标相关联,以相应地对其进行评估。引入了一种技术来简化大量的过程能力信息并将其集中在这个专门的早期决策所需的信息上。在设计师的初步输入之后,算法自动计算最佳工艺选择作为预期订单数量的函数。三个说明性案例研究证明了这种 DFXM 方法在代表性设计场景中的实际应用。
更新日期:2019-09-18
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