Thesis Results Manufacturability & Cost Evaluation · 2019. 6. 24. · Design n Design Time Cost...

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Thesis Results –Manufacturability & Cost EvaluationNachiketh Prabhu | Ranjan Sarapady

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6/17/2019 2

• Introduction

− Background, Current Problem, Goal & Objectives

• Results

− Formability Index

− Software

− Proposed Method

− Case studies

• Conclusions & Further Study

• Questions & Suggestions

AGENDA

Info NXDC/ Ranjan & Nachiketh / Thesis Results

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• SCANIA exhaust department working on silencer designs

• Simulation Driven Design allows for automatic concept evaluation to arrive at best possible design

• Previous work on FEM, CFD and acoustic

• This thesis focuses on implementation of design cost and manufacturability

6/17/2019 3

Background

INTRODUCTION

Costing & ManufacturabilityInfo NXDC/ Ranjan & Nachiketh / Thesis Results

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6/17/2019 4

Current Problem & Goal

Design Engineer

FEM

CFDPhysical Testing

Design Loop

Design 1

Design 2

Design 3

Design n

Design Time

Cost

Manufacturability

F(x) F(x+1)

C(x)

C(x+1)

M(x)

M(x+1)

Cnew(x+1)

C1 C2

C3 Cn-1

M1 M2M3 Mn-1 Mnew(x+1)

Costing & Manufacturability

Time

INTRODUCTION


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• Learn present development process, third party software used at SCANIA

• Develop and implement a methodology for cost estimation and manufacturability of a parametric CAD model

• Implementation of methodology under the current MDO environment through automation

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Objectives

INTRODUCTION


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2019-06-17 6

Research Questions


RQ.1 • How effective is the correlation observed between Cost and

Manufacturability in complex sheetmetal parts?

RQ.2

• Is the integration of Cost estimation and evaluation of manufacturability on parametric CAD models be done along with FEM, CFD and acoustic in the iterative design process? If yes then where in the proposed method can it be done and how effective it is?

RQ.3 • How is the method developed suitable for a different kind of critical

manufacturing process other than sheet metal operation?

RQ.4• How effective is the proposed approach as far as time cost compared

with the current process?

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• Complicated surfaces due to acoustics and back pressure reasons.

• New approach for manufacturing complex form is required

• Solution: Form/ Stamp simulation software

Info NXDC/ Ranjan & Nachiketh / Thesis Results 7

Formability

6/17/2019

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• Applicable with sheetmetal forming

• Sheetemetal forms the required shape, satisfy quality requirements, experiencing localized necking and thinning.

• Based stress conditions for different material formability varies.

• Evaluation of sheet metal forming process uses forming limit diagram or Keeler-Goodwin diagram.

14 May 2019 Info NXDC/ Ranjan & Nachiketh / Thesis Results 8

Formability

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SOFTWARE USED

Inspire Form

• Stamping Simulation for sheetmetal

• Used to optimize design

• Check for Manufacturability

• Reduce Material costs

• Other operation such as constrain,

defeatures etc.

Inspire Form

• Import CATIA model

Extract Face

• Create Mid-Surface

• define thickness

6/17/2019 Info NXDC/ Ranjan & Nachiketh / Thesis Results

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6/17/2019 Ifo NXDC/ Ranjan & Nachiketh / Thesis Results 10

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OUTPUT REPORT FROM INSPIRE

Max < 30%

Formability

Thinning

Nesting/FitThinning < 30%

14 May 2019 Info NXDC/ Ranjan & Nachiketh / Thesis Results6/17/2019

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SOFTWARE USED

Apriori

• Import CATIA model

Input requireddata

• Material, Thickness

• Region of Manufacturing

• ManufacturingProcess

• Production Volume

• Other Data

Run for Cost

• Cost Summary

• Detailed cost breakdown

• Tools required

• Possible DFM analysis

6/17/2019 Info NXDC / Ranjan & Nachiketh / Thesis ResultsInfo NXDC/ Ranjan & Nachiketh / Thesis Results

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COST DETAILS FROM APRIORI

• Material, Thickness

• Region of Manufacturing

• ManufacturingProcess

• Production Volume

• Other Data

CostingInput

India Germany

• Nesting output

• Cost breakdown and comparison

6/17/2019 Info NXDC / Ranjan & Nachiketh / Thesis Results

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6/17/2019 Info NXDC/ Ranjan & Nachiketh / Thesis Results 14

Formability Index FI

• If a part with results of thinning percentage is less than 10% then FI is always 100.

• Hence sheetmetal part with 100 FI is easy to form/stamp.

• Lower the Formability Index (FI) value better is the manufacturability.

RESULTS

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MethodRESULTS

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• Create Parameters required for manufacturability:

− Design rules like Bend allowance, hole positions etc.

− Material variations

− Blank thickness

• Data Exchange:

− Parameterisation due to other control factors like CFD, FEM, Acoustics etc.

− Definition of design Objectives and constraints with the help of different disciplines of departments

2019-06-17 Info NXDC/ Ranjan & Nachiketh / Thesis Results 16

Design phase

RESULTS

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Formability

• Brute Automation

− Visual studio using C#

− TestStack White UI Automation tool

− Excel and Text file as a handshake file to get output


Inspire Automation

InspireForm

Excel+

Notepad

Visual Studio

CAD

Note: No API available in InspireForm

RESULTS

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• Step1:


Analyse & Validation phase

RESULTS

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• Step2:



RESULTS

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• Step3:



RESULTS

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• Step3:



RESULTS

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• Step4:



RESULTS

Validate:

• Check and Validate withDesign Objectives

• Filter the designs by design constraints on FI

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• Step4:



RESULTS

Validate:

• Check and Validate withDesign Objectives

• Filter the designs by design constraints on FI

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Design Improvement

RESULTS

HEEDS

Test1.exe

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PART ANALYSIS FOR COSTING AND MANUFACTURABILITY

Jacket 1

• Improved Designs by reducing FI by 15%

• Correlation between part cost and FI

RESULTS

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PART ANALYSIS FOR COSTING AND MANUFACTURABILITY

2019-06-17

Jacket 2

• Improved Designs by reducing FI by 30%

• No correlation between part cost and FIInfo NXDC / Ranjan & Nachiketh / Thesis Results

RESULTS


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TIME savings

2019-06-17 Info NXDC / Ranjan & Nachiketh / Thesis Results

RESULTS

• Current process for single design evaluation: days or a week

− Designer seek feedback from Suppliers and cost engineers on regular basis

• Proposed method Multiple design evaluations: Completed in hours

− This is just a ballpark estimation

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• Methodology for Designing for Manufacturability and Costing

• Integration of Manufacturability and Cost evaluation towards ‘Simulation Driven Design’

• Successfully tested the feasibility for automated evaluations of CAD designs for manufacturability

• The current methodology is only applicable for Sheetmetal parts but can be expanded to other Manufacturing processes

• Flexible and can be implemented in any phase of the PD process


Conclusion

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• Expand to other manufacturing areas

• Improve automation for InspireForm

• Implement automation in Apriori

• Develop user manual

• Improve the test method

− Real time testing

− User feedbacks and evaluations


Further Study

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THANK YOU

Questions & Suggestions?

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Thesis Results Manufacturability & Cost Evaluation · 2019. 6. 24. · Design n Design Time Cost...

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