An integrated DFMA–PDM model for the design and analysis of challenging similar and dissimilar welds

Tasalloti, H.; Eskelinen, Harri; Kah, Paul; Martikainen, Jukka

doi:10.1016/j.matdes.2015.10.012

Cited by 20 publications

(27 citation statements)

References 17 publications

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“…These sub-sets were then integrated into different vehicles. For example, at the beginning of the year 2000, the Volkswagen Group manufactured all models of all its brands on four distinct platforms; eventually it changed to a new conception based on modular architecture, itself based on assembly-oriented design (Design for Assembly, or DFA) (Tasalloti et al, 2016;Bogue, 2012). That transformation solved some of the aforementioned problems of lean manufacturing: it took advantage of the cost reductions implied by the standardization and simplification of tasks, without losing the competitiveness derived from the adaptation of a product to consumer tastes -i.e., "simplification and reduction of costs in engineering processes, design, and development; flexibility of production; and the search for economies of scale on a global level (greater purchasing power)" (Lampón & Cabanelas, 2014: 18).…”

Section: Modularization Of the Production Process And Its Effects On mentioning

confidence: 99%

Analysis of the effects of the modular design model of car production on working conditions: The cases of VW Navarra and PSA Vigo

Calle¹,

Ramos²,

Ruiz-Gálvez³

2020

Economics &Amp; Sociology

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Following the implementation of new systems of automobile manufacturing based on modular design, we undertook the study of changes in the working conditions of this sector. We choose to further explore these models of productive organization and their effects on working conditions in the automotive sector in Spain. Specifically, we focused on two of the most important plants in the Spanish automotive sector, PSA Vigo and VW Navarra, where new assembly systems have been applied on modular platforms. In our research, we adopted an analytical approach that would allow us address the complexity of this new production model, combining variables (profitability strategy, productive specialization, technical and social organization) and dimensions (within the Group, intra-company, inter-firm) through comparison of the two case studies. Our análisis represents a useful, functional way of studying the intrinsic organizational and productive aspects of current manufacturing processes, reflected in the working conditions and in the factors determining them.

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Section: Modularization Of the Production Process And Its Effects On mentioning

confidence: 99%

Analysis of the effects of the modular design model of car production on working conditions: The cases of VW Navarra and PSA Vigo

Calle¹,

Ramos²,

Ruiz-Gálvez³

2020

Economics &Amp; Sociology

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“…The quality of a welded aero-component can be affected by multiple factors such as welding process parameters and set-up, materials composition, weld joint design, fixture design, product form division, and product geometry [19,20]. The interaction of product geometry and welding process causes welding engineers to struggle because they need to find a new optimal set of process parameters for every new component geometry and material to produces a good welded joint.…”

Section: Introductionmentioning

confidence: 99%

A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications

et al. 2019

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During multidisciplinary design of welded aircraft components, designs are principally optimized upon component performance, employing well-established modelling and simulation techniques. On the contrary, because of the complexity of modelling welding process phenomena, much of the welding experimentation relies on physical testing, which means welding producibility aspects are considered after the design has already been established. In addition, welding optimization research mainly focuses on welding process parameters, overlooking the potential impact of product design. As a consequence, redesign loops and welding rework increases product cost. To solve these problems, in this article, a novel method that combines the benefits of design of experiments (DOE) techniques with welding simulation is presented. The aim of the virtual design of experiments method is to model and optimize the effect of design and welding parameters interactions early in the design process. The method is explained through a case study, in which weld bead penetration and distortion are quality responses to optimize. First, a small number of physical welds are conducted to develop and tune the welding simulation. From this activity, a new combined heat source model is presented. Thereafter, the DOE technique optimal design is employed to design an experimental matrix that enables the conjointly incorporation of design and welding parameters. Welding simulations are then run and a response function is obtained. With virtual experiments, a large number of design and welding parameter combinations can be tested in a short time. In conclusion, the creation of a meta-model allows for performing welding producibility optimization and robustness analyses during early design phases of aircraft components.

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“…Some of these fabricated components employ welding as the main assembly technique. Welding is a complex operation during which the quality of the welded structure is affected by many factors, including welding process parameters, the weld joint geometry, fixture designs, product form division and product geometry [2].…”

Section: Introductionmentioning

confidence: 99%

“…Among this literature, two main fields can be distinguished for their contributions: Engineering Design and Welding Engineering. Within the first field, researchers contribute to Engineering Design by presenting DFM selection tools and methodologies for evaluating alternative designs, materials and welding processing options at the early design stages [2,[12][13][14][15]. All these DFM methods are created on the basis that manufacturability and cost criteria are known.…”

Section: Introductionmentioning

confidence: 99%

A Welding Capability Assessment Method (WCAM) to support multidisciplinary design of aircraft structures

Madrid

Forslund

Söderberg

et al. 2017

Int J Interact Des Manuf

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Designing aircraft engines is a complex process in which requirements from multiple disciplines need to be considered. Decisions about product geometry and tolerances to achieve optimized aerodynamics, product life and weight can affect the manufacturing process. Therefore, providing information to designers about process capabilities is necessary to support design exploration and analysis. In this paper, the authors propose the Welding Capability Assessment Method (WCAM) as a tool to support the systematic identification and assessment of design issues related to product geometry critical to the welding process. Within this method, a list of potential failure modes during welding is connected to specific design parameters. Once the critical design parameters have been identified, quantitative methods are proposed to calculate tolerances to reduce the likelihood of welding failures. The application of this method is demonstrated through an industrial case study where a combination of interviews and welding simulations is used to study the welding capability of a number of product geometries. This method represents an advancement from traditional qualitative guidelines and expert judgments about welding difficulties towards a more quantitative approach, supporting virtual design.

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An integrated DFMA–PDM model for the design and analysis of challenging similar and dissimilar welds

Cited by 20 publications

References 17 publications

Analysis of the effects of the modular design model of car production on working conditions: The cases of VW Navarra and PSA Vigo

Analysis of the effects of the modular design model of car production on working conditions: The cases of VW Navarra and PSA Vigo

A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications

A Welding Capability Assessment Method (WCAM) to support multidisciplinary design of aircraft structures

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