Preface	5
	Contents	7
	Contributors	9
	Abbreviations	12
	Symbols	14
	Chapter 1: Introduction: Production Technologies and Product Development	18
	1.1 The Interaction Between Product Development and Production Technology	18
	1.2 Incorporation of Production in Current Product Development Approaches	19
	1.3 Market Pull vs. Technology Push	23
	References	25
	Chapter 2: The CRC666 Approach: Realizing Optimized Solutions Based on Production Technological Innovation	27
	2.1 Motivation for and Goals of a New Development Approach	27
	2.2 Options in Manufacturing Technologies	29
	2.3 Manufacturing-Induced Properties	33
	2.4 Mathematical Optimization of Product Geometries and Manufacturing Processes	35
	2.4.1 Classification of Optimization Tasks	37
	2.4.2 Examples for Optimization	40
	2.5 Integrated Algorithm-Based Product and Process Development	42
	References	44
	Chapter 3: New Technologies: From Basic Ideas to Mature Technologies	46
	3.1 Basics of Linear Flow Splitting and Bend Splitting	47
	3.1.1 Process Principles	48
	3.1.2 Technology	51
	3.1.3 Process Characteristics	55
	3.1.4 Process Qualification	58
	3.2 Integrated Process Chains for Sheet Metal Structures	65
	3.2.1 Roll Forming	67
	3.2.2 Cutting Technologies	71
	3.2.3 Welding	91
	3.2.4 Deep Drawing	93
	3.2.5 Process Control	102
	3.3 Product Benefits Through Bifurcations	107
	3.3.1 Bifurcation at the Edge of Sheet Metal	107
	3.3.2 Bifurcation in the Plane of Sheet Metal	108
	References	109
	Chapter 4: Manufacturing Induced Properties: Determination, Understanding, and Beneficial Use	113
	4.1 Effects of Severe Straining in Integral Sheet Metal Design	114
	4.1.1 Strength	121
	4.1.2 Subsequent Formability	125
	4.1.3 Durability	129
	4.1.4 Rolling Contact Fatigue	140
	4.2 Processing of Manufacturing-Induced Properties for Product Development	146
	4.2.1 Linking Manufacturing-Induced Properties to Functional Product Properties	147
	4.2.2 Preparation and Documentation of Process-Integrated Design Guidelines	149
	4.3 Benefits: Some Examples	150
	4.3.1 Mathematical Optimization of Stringer Sheets	150
	4.3.2 Light Crane System	153
	References	156
	Chapter 5: Finding the Best: Mathematical Optimization Based on Product and Process Requirements	160
	5.1 Formalization of the Design Task	162
	5.1.1 Modeling of Technical Systems by Properties	163
	5.1.2 Requirement Acquisition and Transformation into Properties	167
	5.1.3 Integration of Manufacturing Technologies	172
	5.1.4 Formalized Integrated Product and Process Design Task	176
	5.2 Optimization of Product Design	178
	5.2.1 Geometry Optimization of Multi-Chambered Profiles	182
	Algorithm 5.1 (SQP with l1-penalty globalization)	183
	5.2.2 Topology and Geometry Optimization: A Combined Approach	184
	5.2.3 Geometry Optimization of Hydroformed Branched Sheet Metal Products	188
	5.2.4 Shape Optimization of Mechanical Connections	190
	5.3 Process Optimization	194
	5.3.1 Optimal Control of Deep Drawing Processes	194
	Algorithm 5.2 (Bundle-ROM-based Trust Region algorithm with Levenberg regularization)	201
	5.3.2 Partitioning	202
	Algorithm 5.3 (Brute-force algorithm for finding an optimal partition)	205
	5.3.3 Production Sequence	206
	5.4 Beneficial Effects of Formalization and Optimization	208
	References	209
	Chapter 6: Computer-Integrated Engineering and Design	214
	6.1 Integrated Information Model	217
	6.1.1 Core Model	218
	6.1.2 Products and Production Processes	221
	6.2 CAD Modeling for Bifurcated Sheet Metal Parts	224
	6.2.1 Direct Modeling Approach	225
	6.2.2 Algorithmic Modeling Approach	231
	6.2.3 Panelization of Freeform Building Facades	235
	6.3 Process Simulation	237
	6.3.1 Linear Flow Splitting Simulation of the Macro Geometry	237
	6.3.2 Simulation of Local Properties	242
	6.4 Fatigue Strength Simulation	245
	6.4.1 Linear Flow Split Structures	245
	6.4.2 Deep Drawn Structures	250
	References	253
	Chapter 7: New Challenges: Technology Integrated Market-Pull	257
	7.1 New Processes	258
	7.1.1 Integrated Bending	258
	7.1.2 Flexible Flow Splitting	261
	7.2 New Products of Sheet Metal Panels	272
	7.2.1 Panelization of Free-Form Architecture Using Flexible Modules	272
	7.2.2 Joints with Flow Split Flanges	276
	7.2.3 Multifunctional Building Modules	277
	7.3 Implementation of Our Approach on Aesthetical Demands	282
	References	285
	Chapter 8: Finding New Opportunities: Technology Push Approach	287
	8.1 Technology-Pushed Product Innovation	288
	8.1.1 From Manufacturing-Induced Properties to Product Innovation	289
	8.1.2 Linear Flow Split Linear Guides	291
	8.2 Technology-Pushed Process Innovation	298
	8.2.1 Process Innovation Driven by Manufacturing-Induced Properties	299
	8.2.2 Mechanical Joining by Linear Flow Splitting	302
	8.3 Concurrent Technology-Pushed Product and Process Innovation	309
	References	310
	Chapter 9: The Result: A New Design Paradigm	312
	9.1 Integrated Algorithm-Based Product and Process Development	313
	9.1.1 The Integrated Approach	313
	9.1.2 Impacts of the Integrated Approach	316
	9.2 Case Studies	320
	9.2.1 Facade Cleaning System	320
	9.2.2 Integrated Fastenings for Hangers	331
	9.2.3 Nonlinear Skywalk Beam	337
	References	345
	Index	346