Session: DFMLC-02-02: Design for Manufacturing, Assembly, and Integration

Paper Number: 144084

144084 - Structural Design Vs Manufacturability Costs of Complex Stamped Components 

This paper presents a study of tradeoffs between design and manufacturing objectives for complex sheet metal stamped components, taking into account both topological (shape) and size variants of geometric features. The study artifact is the support frame of automotive hoods for a given outer skin. Traditional optimization methods, such as Design of Experiments (DOE)/Response Surface Optimization (RSO), mathematical algorithms, and GA, are not suitable because different feature shapes cannot be described by a given set of uniform design variables. A large data set of shape and size variants for automotive hood frames was curated for the study. Work has already been completed on generating geometric data sets and evaluating their structural design objectives. In this paper, we focus on manufacturing cost as a metric for manufacturability. We look at both the material and process costs, the latter determined indirectly via press loads for trimming and drawing operations, to find the press loads associated with manufacturing processes used to produce the hood designs already available in the 10k hood dataset. A 10% sampling was used in the stamping simulation from which response surfaces were created to use in completing manufacturability responses on all (almost) all 10,000 designs in the data set.

Presenting Author: Satchit Ramnath Clemson University

Presenting Author Biography: Assistant Professor in Mechanical Engineering at Clemson University.

Authors:

Ibraheem Alawadhi The Ohio State University
Satchit Ramnath Clemson University
Abhishek Bolar The Ohio State University
Yilin Fu The Ohio State University
Jami Shah The Ohio State University
Nathan Zurbrugg Honda Development and Manufacturing America LLC
Duane Detwiler Honda Research Institute - Ohio