Scalable Set-Based Design Optimization and Remanufacturing for Meeting Changing Requirements

Abstract

Design requirements are often uncertain in the early stages of product development. Set-based design (SBD) is a paradigm for exploring, and keeping under consideration, several alternatives so that commitment to a single design can be delayed until requirements are settled. In addition, requirements may change over the lifetime of a component or a system. Novel manufacturing technologies may enable designs to be remanufactured to meet changed requirements. By considering this capability during the (SBD) optimization process, solutions can be scaled to meet evolving requirements and customer specifications even after commitment. Such an ability can also support a circular economy paradigm based on the return of used or discarded components and systems to working condition. We propose a (SBD) methodology to obtain scalable optimal solutions that can satisfy changing requirements through remanufacturing. We first use design optimization and surrogate modeling to obtain parametric optimal designs. This set of parametric optimal designs is then reduced to scalable optimal designs by observing a set of transition rules for the manufacturing process used (additive or subtractive). The methodology is demonstrated by means of a structural aeroengine component that is remanufactured by direct energy deposition of a stiffener to meet higher loading requirements

Application of Probabilistic Set-Based Design Exploration on the Energy Management of a Hybrid-Electric Aircraft

“…The aim is to avoid problems that often surface at advanced stages of the design process, which would require a major redesign or reversal of early decisions, prompting an increased cost both in terms of time and resources [36]. Set-Based Design has been recently investigated for the problem of designing products under flexible requirements [37,38], and incorporate resilience to unexpected modes of operation [39]. Furthermore, the large sweeping of the design space combined with a multi-disciplinary model makes SBD principles suitable for design space exploration and trade-off activities of complex systems [40].…”

Intelligent systems for additive manufacturing-based repair in remanufacturing: a systematic review of its potential

“…Researchers such as Al Handawi et al. (2020) highlighted the need to address limitations in AM repair from the perspective of environment, economics and social.…”

The Inclusion of End-of-Life Modeling in the Life Cycle Energy Optimization Methodology

“…Thus, modeling recycling with the equal-share method in the LCEO methodology would result in designs that embody a relatively stronger sustainability concept as they would integrate material flows that would adhere better to conceptualizations of the circular economy [73]. Additionally, further work is needed to expand the LCEO methodology to accommodate strategies that aim at extending the life span of a vehicle and its parts, such as remanufacturing [74]. Such a development of the methodology would lead to optimal solutions that would be compatible with the application of strategies that rank higher on the circularity ladder.…”