Towards Automotive Manufacturing Efficiency: Enhanced Virtual Commissioning Simulation for Dynamic Sheet Metal Handling Optimization

Today many manufacturing firms are focusing on cycle or throughput time reduction to gain a competitive advantage. In many instances, cycle times at individual workstations are adversely affected by unscheduled machine breakdowns. In this paper, existing closed-form approximations for the expected cycle time at a parallel machine workstation with general process and interarrival times and for the variability in departures from the workstation are used to demonstrate how the mean and variance of machine repair or downtime affects cycle times at a given workstation and downstream workstations. Results from the machine interference literature are used to characterize the dependence of repair time on a base stock inventory policy used for the replenishment of spare components. Expressions for the mean and approximations for the variance of repair times are obtained for machines with either a single critical component or a series of critical components when such components fail exponentially. Numerical examples are given to illustrate the effect that spare component inventory levels have on the average station cycle time and departure variability. A methodology for base stock parameter selection that considers the trade-off between reduced cycle times and inventory investment is also presented.

Evaluation of Models for Cooling System Design in Hot Stamping Tools

Prediction of the interpass temperature of a wire arc additive manufactured wall: FEM simulations and artificial neural network

This paper presents the results of finite element method (FEM) simulations of heat-transfer and fluid flow of microchannels. These FEM simulations are used in an actuator placement problem for a microchannel network configuration and in formulating an off line control law with the additional use of proper orthogonal decomposition (POD). In the first part of this paper with the use of FEM simulations we investigate the thermal behavior of different materials in microscale. We propose an actuator placement design that is well suited for microchemical systems. This actuator design coupled with a control action allows variations in the temperature profiles within millimeters. In the second part, we propose a control scheme that is based on a POD of the temperature profiles obtained by FEM simulations. This control scheme uses the optimal eigenfunctions obtained from the POD procedure in a minimization procedure that results in the appropriate change in the manipulated input variables.

Introduction. Bond strength between dissimilar materials is the most important characteristic of laminated composites, which determines the success of its development for industrial use. In order to develop the theory of joining materials by plastic deformation, it is proposed to perform computer simulation of joint deformation of representative volumes of dissimilar materials on a microscale and compare the parameters of the stress-strain state with the previously presented theoretical mechanism. The aim of this work is to analyze the stress-strain state of dissimilar materials under plastic deformation on a microscale and to establish the location of the onset of fracture of surface oxide films. To achieve this aim, the following tasks of the work are formulated: 1) to study the surface profiles of dissimilar materials to be bonded by plastic deformation; 2) to simulate by the finite element method (FE) the plastic deformation of contact surfaces of dissimilar materials on a microscale; 3) to study the stages of joint deformation of dissimilar materials on a microscale and verify of the theoretical mechanism. Research methodology. The study of three-dimensional topography and roughness was carried out on a Veeco Wyko NT1100 Optical Profiling System. Deform-3D FE simulation package was chosen as the main research tool. Aluminum alloys AMg3 and D16 were chosen as the materials under study. Results and discussion. In this work, computer FE simulating of the joint deformation of the surface layers of AMg3 and D16 alloys on a microscale was performed, an analysis of the surface profiles of materials after various types of processing was carried out, the parameters of the stress-strain state were studied and compared with the parameters of the theoretical mechanism. Based on the results of the comparison, the adequacy of the proposed theoretical mechanism was assessed, and the practical difficulties of theoretical simulation of the joint deformation of dissimilar materials on the microscale were noted. Microscale FE simulation made it possible to study the flow of plastic deformation in the near-surface layers of materials, as well as to identify areas of the most probable fracture of surface oxide films and, consequently, areas of primary bonding of dissimilar materials.

A number of grid-generation and CFD-process software tools have been developed which greatly improve the ability to perform overset CFD analysis of complex con gurations. These tools have been applied to the task of generating grids and computing the ow eld about two di erent high-lift aircraft con gured for landing: a Boeing 777-200, and a High-Wing Transport with externally blown aps. The high-lift owelds of both aircraft were simulated using the OVERFLOW solver. A Navier-Stokes simulation of a complete Boeing 777-200 aircraft con gured for landing was obtained in less than 50 labor days with a lift coe cient which di ers from experimental data by only 1.2%. This is an order of magnitude reduction in the cycle time for the entire computational process compared to a similar high-lift simulation e ort that took place two years earlier. The new software was utilized to perform a oweld analysis of a ap-rigging modi cation for the Boeing 777-200 aircraft in only four days. The software was also utilized to simplify Aerospace Engineer. yChief, Aerospace Operations Modeling O ce. Senior Member AIAA. zResearch Engineer. xPrincipal Engineer. Senior Member AIAA. {Engineer/Scientist Specialist. Member AIAA. kPrincipal Engineer. Copyright c 2000 by the American Institute of Aeronautics and Astronautics, Inc. No copyright is asserted in the United States under Title 17, U.S. Code. The U.S. Government has a royalty-free license to exercise all rights under the copyright claimed herein for Governmental Purposes. All other rights are reserved by the copyright owner. grid generation of the High-Wing Transport for many di erent geometric con gurations. The reductions in computational cycle time are primarily the result of the use of an automatic script system that streamlines the overset grid preparation process. Analysis of the process shows that over-setting the the grid system is now the most labor-intensive part of a single-point analysis; however, for multi-point analyses, multiple viscous ow-solver runs are costly.

The integration of Finite Element Method (FEM) simulations with laser-based techniques has significantly advanced acoustic research by enhancing wave measurement, analysis, and prediction in complex solid media. This review examines the role of the FEM in laser-based acoustics for wave propagation, defect detection, biomedical diagnostics, and engineering applications. FEM models simulate ultrasonic wave generation and propagation in single-layer and multilayered structures, while laser-based experimental techniques provide high-resolution validation, improving modeling accuracy. The synergy between laser-generated ultrasonic waves and FEM simulations enhances defect detection and material integrity assessment, making them invaluable for non-destructive evaluation. In biomedical applications, the FEM aids in tissue characterization and disease detection, while in engineering, its integration with laser-based methods contributes to noise reduction and vibration control. Furthermore, this review provides a comprehensive synthesis of FEM simulations and experimental validation while also highlighting the emerging role of artificial intelligence and machine learning in optimizing FEM models and improving computational efficiency, which has not been addressed in previous studies. Key advancements, challenges, and future research directions in laser-based acoustic applications are discussed.

Prediction of the final part properties in sheet metal forming by CNC-controlled stretch forming

Accelerated product development is a competitive strategy that seeks to reduce the development cycle time of new products. However, there has been little theoretical advancement and empirical model testing in the identification of the conditions under which cycle time reduction is appropriate, the organizational characteristics and practices that accelerate product development, and the precise manner by which cycle time reduction affects project outcomes. Since cycle time reduction has become widely accepted as a key element in managing new‐product development, this contribution organizes and integrates the literature on accelerated product development. Specifically, we argue that the antecedents associated with shorter development cycle time are well known, but that there are inconsistencies with respect to the contextual applicability of cycle time reduction, and contradictory empirical evidence for its alleged merits in achieving lower development costs, better product quality, and greater chance of new‐product success. We attribute these inconclusive results to methodological differences in measurement approach, trade‐offs in cycle time reduction, and the hidden costs of accelerated product development. Moreover, we discuss that it is essential to take the new product's window of opportunity into account while investigating the outcomes of accelerated product development. For scholars, we provide a theoretical foundation for rigorous, empirical research. For practitioners, we list the merits of cycle time reduction, describe the situations in which it is appropriate, and delineate ways how interventions can be applied.

This study establishes the forming limit diagram (FLD) for QSTE340 seamed tube hydroforming by finite element method (FEM) simulation. FLD is commonly obtained from experiment, theoretical calculation and FEM simulation. But for tube hydroforming, both of the experimental and theoretical means are restricted in the application due to the equipment costs and the lack of authoritative theoretical knowledge. In this paper, a novel approach of predicting forming limit using thickness gradient criterion (TGC) is presented for seamed tube hydroforming. Firstly, tube bulge tests and uniaxial tensile tests are performed to obtain the stress‐strain curve for tube three parts. Then one FE model for a classical tube free hydroforming and another FE model for a novel experimental apparatus by applying the lateral compression force and the internal pressure are constructed. After that, the forming limit strain is calculated based on TGC in the FEM simulation. Good agreement between the simulation and experimental results is indicated. By combining the TGC and FEM, an alternative way of predicting forming limit with enough accuracy and convenience is provided.

Press working is a chip-less manufacturing process on sheet metal through the application of immense force with the help of press tools for short interval and hence results in shearing or deformation of the work material. It is a chip-less manufacturing process by which various components are made from sheet metal. A compound die is one that is used for cutting operations only, and the operation is completed by a single-press stroke. In this article, a die was designed to serve the purpose of cutting down the blades for paddy weeder and clearances to be provided in the die were calculated so as to reduce the material consumption with reduction in production cycle time. The die thus designed served for the purpose with 73% reduction in production time, with enhanced quality and helped in enabling mass production by eliminating several processes such as marking, cutting done with the help of a cutter, shaping, and so on.

Design and analysis of aircraft sheet metal for spring back effect

A substantial increase in demand on the sheet metal part usage in aerospace and automotive industries is due to the increase in the sale of these products to ease the transportation. However, due to the increase in fuel prices and further environmental regulation had left no choice but to manufacture more fuel efficient and inexpensive vehicles. These heavy demands force researchers to think outside the box. Many innovative research projects came to replace the conventional sheet metal forming of which single point incremental forming is one of them. SPIF is the emerging die-less sheet metal forming process in which the single point tool incrementally forces any single point of sheet metal at any processing time to undergo plastic deformation. It has several advantages over the conventional process like high process flexibility, elimination of die, complex shape and better formability. Previous literature provides enormous research on formability of metal during this process, process with various metals and hybrid metals, the influence of various process parameter, but residual formability after this process is untouched. Thus, the aim of this paper is to investigate the residual formability of the formed parts using single point incremental forming and then restrike with a conventional tool. The common process parameters of single point incremental forming were varied, and residual formability was studied through the conventional process. The strain and thickness distribution were measured and analyzed. In addition, the forming limit of the part was plotted and compared.

Numerical 3-D FEM simulation of tensor model for liquid crystal displays

External force at the end-effector is often required for the force control of robotic manipulator. In some cases, the force information measured by wrist force sensor consists of the external force and the undesired inertial force arising from the acceleration of the end-effector. Up to now, il: is still difficult to extract the external force exactly for the insufficiency of acceleration information. A novel six-axis accelerometer in. the type of dual annular membranes structure is presented in this paper. It can simultaneously measure all three linear acceleration components a <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">x</sub> , a <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">y</sub> , a <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">z</sub> , and three angular acceleration components a <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">x</sub> , a <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">y</sub> , a <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">z</sub> which can be used to extract the external forces. The Finite Element Method (FEM) simulations were carried out to optimize the configuration of strain gauges. The analysis of the rated strains and interference strains indicates that the accelerometer has a low level cross-sensitivity. The characteristic experiment shows that the linearity of the accelerometer is good with minor interference errors. It also reveals that the rated strains and interference strains are in good correspondence with the results from the FEM simulations.