FE Simulation-Based Folding Defect Prediction and Avoidance in Forging of Axially Symmetrical Flanged Components

2010 ◽  
Vol 132 (5) ◽  
Author(s):  
W. L. Chan ◽  
M. W. Fu ◽  
J. Lu
Keyword(s):  
Product Development ◽  
Product Design ◽  
Material Flow ◽  
Fe Simulation ◽  
Flow Behavior ◽  
Defect Prediction ◽  
Induced Folding ◽  
Folding Defect ◽  
Defect Avoidance ◽  
Development Paradigm

In the traditional metal forming product development paradigm, product design is generally based on heuristic know-how and experience, which are basically acquired through many years of practice. This kind of product design paradigm is of more trial-and-error than in-depth scientific calculation and analysis. Product defect prediction and quality assurance is, thus, a nontrivial issue in this product development paradigm. With the aid of finite element (FE) simulation, deformation-related defects can be predicted and analyzed. In this paper, flow-induced folding defect in forging of axially symmetrical flanged components is systematically investigated. A FE model to study the root-cause of the defect based on the material flow behavior is developed and a defect formation mechanism is revealed. The variation of material flow behavior with the changes of part geometry parameters is investigated extensively. Based on the simulation results, the parameter variation characteristics and the sensitivity of each parameter to folding defect avoidance are identified. Using industrial components as case studies, the efficiency of the proposed defect avoidance approach is verified. The approach is further proven to be able to provide practical guidelines for the design of defect-free axially symmetrical flanged components.

Truck Redesign Case: Simulating the Target Costing Process in a Product Design Environment

2013 ◽  
Vol 29 (1) ◽  
pp. 61-85 ◽  
Author(s):  
Patricia Everaert ◽  
Dan W. Swenson
Keyword(s):  
Product Development ◽  
Product Design ◽  
Goal Setting ◽  
Cost Reduction ◽  
Data Availability ◽  
Design Stage ◽  
Target Costing ◽  
Design Environment ◽  
Goal Setting Theory ◽  
Setting Theory

ABSTRACT This active learning exercise simulates the target costing process and demonstrates how a management theory (goal setting theory) is relevant to a business improvement initiative (target costing). As part of the target costing simulation, student participants work in teams to address a business issue (product development) that moves across functional boundaries. The simulation begins with students learning how to assemble a model truck and calculate its product cost using activity-based costing. Students are then divided into teams and instructed to reduce the truck's cost through a redesign exercise, subject to certain customer requirements and quality constraints. Typically, the teams achieve cost reduction by eliminating unnecessary parts, by using less expensive parts, and by using less part variety. This exercise provides a unique opportunity for students to actively participate in a redesign exercise. It results in student teams creating a wide variety of truck designs with vastly different product costs. The case ends by having a discussion about target costing, goal setting theory, and the implications of the target costing simulation. This simulation contains a number of specific learning objectives. First, students learn how the greatest opportunity for cost reduction occurs during the product design stage of the product development cycle. Second, students see firsthand how design-change decisions affect a product's costs, and the role of the cost information in guiding those decisions. Third, students experience the cross-functional interaction that occurs between sales and marketing, design engineering, and accounting during product development. Finally, this exercise helps students understand the concept of target costing. The simulation is appropriate for undergraduate or graduate management accounting classes. Data Availability:  For more information about this case, contact the first author at [email protected].

Proposed Method for Sustainability Development of Consumable Goods

2014 ◽  
Vol 1061-1062 ◽  
pp. 1233-1237 ◽  
Author(s):  
Pâmela Teixeira Fernandes ◽  
Osíris Canciglieri ◽  
Ângelo Márcio Oliveira Sant’Anna
Keyword(s):  
Literature Review ◽  
Product Development ◽  
Product Design ◽  
Development Process ◽  
Product Development Process ◽  
Promising Solution ◽  
Sustainable Projects

This paper presents the findings of research exploring how designers could to evaluate and insert sustainability requirements in product design during the initial stages of the product development process. It describes the process of development of the method for sustainability consumable goods based from a literature review and explores its application in the development of packaging for cosmetic. The results show that the use of the method may be a promising solution for sustainable projects, providing the insertion of the reasoning for the inclusion of product development oriented to sustainability as a complement to traditional project requirements that existing in the models of product development.

Application of Rapid Prototyping Technology in Product Design

2014 ◽  
Vol 989-994 ◽  
pp. 3208-3211
Author(s):  
Dan Tong Li ◽  
Zheng Zhang ◽  
Jia Wen Deng ◽  
Ming Yu Huang ◽  
Xiao Feng Wan ◽  
...  
Keyword(s):  
Product Development ◽  
Rapid Prototyping ◽  
Product Design ◽  
New Product Development ◽  
Medical Model ◽  
New Product ◽  
Mechanical Parts

The rapid prototyping technology was introduced, including its definition, principle and characteristics. The advantages of rapid prototyping technology in new product development were analyzed. Application of rapid prototyping technology in design of mechanical parts, industrial model, medical model, ceramic products, automobile model and products based on ergonomics was discussed. The feasibility of rapid prototyping technology in product design and the optimization direction was prospected.

Influence of Tool Geometry and Contact Condition on Friction Stir Welding of Al-Cu Laminated Composites

2013 ◽  
Vol 856 ◽  
pp. 16-21
Author(s):  
R. Beygi ◽  
Mohsen Kazeminezhad ◽  
A.H. Kokabi ◽  
S. Mohammad Javad Alvani ◽  
D. Verdera ◽  
...  
Keyword(s):  
Friction Stir Welding ◽  
Material Flow ◽  
Laminated Composites ◽  
Flow Behavior ◽  
Tool Geometry ◽  
Contact Conditions ◽  
Friction Stir ◽  
Tool Geometries ◽  
Welding Procedure ◽  
Sem Analyses

In this study friction stir welding of Al-Cu laminated composites were carried out by two different tool geometries. Welding procedure was carried out from both sides of Al and Cu. Analyzing cross section of welds showed that different contact conditions between shoulder and material, offers different material flow behavior which is dependent on the tool geometry. SEM analyses showed that mixing of materials in nugget region is more pronounced in the advancing side. Also XRD results indicated that welding from Cu side, leads to intermetallic formation in mixed regions.

Tool Approach Directions for Machining Protrusion and Depression Features in an Object

1990 ◽  
Author(s):  
Chandrasekhar Karra ◽  
Thomas A. Phelps
Keyword(s):  
Product Development ◽  
Product Design ◽  
Tool Path ◽  
Low Cost ◽  
Production Costs ◽  
Competitive Market ◽  
Process Plans ◽  
Manufacturing Problems ◽  
Lower Production

Abstract The success of any industry in today’s highly competitive market is largely dependent on its ability to produce quality products, quickly and at low cost. Evaluating the effect of a product design on its manufacture is crucial in developing efficient designs. Any potential manufacturing problems detected at this stage can be corrected by modifying the design, leading to shorter product development cycles and lower production costs. This paper presents an algorithm to determine feasible tool approach directions. The algorithm is based on detecting if any part of the object obstructs the tool path. The basis for the algorithm is determining feasible approach directions and clearances around a planar polygonal face. The algorithm is applicable to both protrusions and depressions. The information is useful in performing manufacturability analysis of designs and develop process plans.

scholarly journals Development of Product and Packaging Label for Kao-Taen (Rice Cracker) of the Agro-group of Kao Kwang Tong Sub-district, Nong Chang District, Uthaithani Province

2016 ◽  
Vol 12 (8) ◽  
pp. 171 ◽  
Author(s):  
Tawat Payim
Keyword(s):  
Product Development ◽  
Product Design ◽  
Low Cost ◽  
Key Factors ◽  
Research Results

<p>This research was aimed to develop the product and packaging label for Kao-Taen (rice cracker) of the agro-group of Kao Kwang Tong sub-district, Nong-Chang district, Uthaithani province. It explored and developed Kao-Taen product using materials within the community, and evaluated the product design and packaging label by specialists. <strong></strong></p><p>The research results suggested the outcome of product development, with Kao-Taen of 3 cm. in diameter and 1.5 cm. thick, the size allows for more convenient consumption by consumers. The design of packaging label in style 3 with mean 4.92 was considered most appropriate. The key factors contributing to the community product development included available materials in the community, community’s self-capability, presentation of community uniqueness, and low cost. </p>

scholarly journals Computer aided product design tool for sustainable product development

2014 ◽  
Vol 71 ◽  
pp. 362-376 ◽  
Author(s):  
Juliette Heintz ◽  
Jean-Pierre Belaud ◽  
Nishant Pandya ◽  
Moises Teles Dos Santos ◽  
Vincent Gerbaud
Keyword(s):  
Product Development ◽  
Product Design ◽  
Design Tool ◽  
Computer Aided ◽  
Sustainable Product Development ◽  
Sustainable Product

Material flow behavior modeling with consideration of size effects

Rare Metals ◽  
2018 ◽  
Vol 37 (11) ◽  
pp. 995-1002 ◽  
Author(s):  
Zhen-Wu Ma ◽  
Zi-Yang Cao ◽  
Jin-Bin Lu ◽  
Hua Li ◽  
Yuan-Jing Zhang ◽  
...  
Keyword(s):  
Size Effects ◽  
Material Flow ◽  
Flow Behavior ◽  
Behavior Modeling
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