In the product development process testing and validation is necessary to certify the function of the product, but it is time and cost extensive. A high ratio between output and input effort has to be aimed. To reach this effect a hierarchy of test levels is sensible. This paper shows an approach to describe and map the transferability of boundary conditions between these scale levels and model layers. The chosen scale levels are material, structure and product level and the model layers are reality, physical and virtual models. The challenges of the transferability of boundary conditions will be shown for three research topics, static testing for cylinders, optimization of sandwich inserts and dynamic testing of cabin interior.
This paper presents how numerical optimization methods, like topology optimization, and new design possibilities through additive manufacturing (AM) can be used for structural improvements of the load introduction points in sandwich structures. A new design approach is presented, which allows a direct load-path optimized integration of the load introduction point into the sandwich core. The corresponding methodical procedure is shown and the application is demonstrated exemplarily for a sandwich structure with a honeycomb core. The advantages for design science are that the new design possibilities of AM can be considered and used when designing the load introduction points. Thus, the additional reinforcements of the sandwich structures to absorb locally introduced forces in the lightweight structure can be minimized. This enables a meaningful technical comparison and it can be decided in the future whether such a design can be used for sandwich structures under economic aspects. In addition, the influence of the initial and boundary conditions on the design is presented and discussed in this paper. The challenges of optimizing multiple load introduction points simultaneously as well as the special aspects to be considered when transferring the design approach to larger sandwich structures are also highlighted.
In methodical product development, numerous data are used and linked with each other, especially variant-related data. This paper presents a model-based solution for avoiding inconsistencies in the development of product families with many variants and extends it to modular lightweight design. In addition, the inconsistencies in methodical product development were classified and solution approaches were shown. Thus, inconsistencies can be avoided with the presented elaborated data model for an integrated product and process model based on the presented procedure.
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