Interdisciplinary design of components with complex functional surfaces under consideration of manufacturing constraints

 

In the conventional development of components with complex functional surfaces, the design is adapted in particular to the function and structural mechanics of the component. Once a fixed geometry has been defined in a highly iterative design process, the possibilities for subsequent modification or adaptation of the design are limited.

A shortcoming of this approach is that manufacturing aspects are not included in the design process. This often leads to process-related inefficiencies in the ramp-up phase that reduce component efficiency from the perspective of the design disciplines compared to the theoretical optimum. However, there is potentially a much wider solution domain for the final geometry if knowledge of manufacturing and machine behavior is incorporated in the early stages of development. At present, however, the early involvement of manufacturing in the development process has not been implemented in a systematic and methodical way.

One possible approach is "simultaneous engineering," in which an interdisciplinary intersection of the component-specific solution domain is created at an early design stage. This can increase the efficiency of the development and manufacturing process. Although there are already approaches in engine design that address the compatibility of aerodynamics and structural mechanics, manufacturing and production have not yet been included.

The DFG research project "Interdisciplinary design of components with complex functional surfaces under consideration of manufacturing constraints" aims to develop a methodology for considering manufacturing constraints in the early stages of component design. Using the Blisk (Blade Integrated Disk) engine component as an example, this methodology is intended to overcome current limitations and increase efficiency in the development and manufacture of components with complex functional surfaces. By incorporating manufacturing knowledge at an early stage, the goal is to generate geometries in the design that meet the performance requirements of the component and enable a more efficient and stable manufacturing process. For such an approach, it is necessary that the methodology to be developed, with which a direct exchange between manufacturing and other disciplines takes place at the beginning of the design, is based on a concrete requirement profile for the design.

The analysis and preparation of relevant criteria play a critical role in adding value to component design. A mature methodology that enables productive exchange between manufacturing and other engineering disciplines during the design phase of a complex component can add both technological and economic value and promote a holistic approach to product design.