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