Abstract
Individualized production, which is a major goal of many high-wage countries, describes a production process in which all elements of a production system are designed in such a way that they enable a high level of product variety at mass production costs. This paper demonstrates recent advances in the individualized production with die-based manufacturing processes, namely high-pressure die casting and plastics profile extrusion. Within these application areas, the chosen approach aiming at individualized production is based on the use of numerical die and process design. The design procedure relies on numerical process simulations based on a nonlinear optimization library and a spline-based geometry kernel. All components interact automatically without requiring user interaction; thus, a completely independent optimization cycle can be achieved. The numerical optimization helps to reduce—or even eliminate—the so far very characteristic manual reworking steps of an original die or process design. These reworking steps are a major cost factor when it comes to individual production. Their abolishment through the presented numerical approaches therefore represents a large step towards the concept of individualized production.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Behr M (1992) Stabilized finite element methods for incompressible flows with emphasis on moving boundaries and interfaces. Ph.D. thesis, University of Minnesota
Brecher C, Jeschke S, Schuh G, Aghassi S, Arnoscht J, Bauhoff F, Fuchs S, Jooß C, Karmann WO, Kozielski S, et al. (2012) Integrative production technology for high-wage countries. Springer
Carneiro O, Nóbrega J, Pinho F, Oliveira P (2001) Computer aided rheological design of extrusion dies for profiles. J Mater Process Technol 114(1):75–86
Debbaut B, Marchal T (2008) Numerical simulation of extrusion process and die design for industrial profile, using multimode pom–pom model. Plastics, rubber and composites 37(2-4):142–150
Elgeti S, Probst M, Windeck C, Behr M, Michaeli W, Hopmann C (2012) Numerical shape optimization as an approach to extrusion die design. Finite Elem Anal Des 61:35–43
Esparza CE, Guerrero-Mata MP, Ríos-Mercado RZ (2006) Optimal design of gating systems by gradient search methods. Comput Mater Sci 36(4):457–467
Ettinger H, Pittman J, Sienz J (2013) Optimization-driven design of dies for profile extrusion: Parameterization, strategy, and performance. Polym Eng Sci 53(1):189–203
Ettinger H, Sienz J, Pittman J, Polynkin A (2004) Parameterization and optimization strategies for the automated design of upvc profile extrusion dies. Struct Multidiscip Optim 28(2-3):180–194
Flender E, Sturm J (2010) Thirty years of casting process simulation. Int J Met 4(2):7
Gonçalves N, Carneiro O, Nóbrega J (2013) Design of complex profile extrusion dies through numerical modeling. J Non-Newtonian Fluid Mech 200:103–110
Griewank A, Walther A (2008) Evaluating derivatives: principles and techniques of algorithmic differentiation. SIAM
Hilbinger M, Koepf J, Rbner V, Singer R (2012) Computational optimisation of plunger movement during slow shot phase in high pressure diecasting. Foundry Trade Journal International 186(3699):291–294
Hopmann C, Windeck C, Kurth K, Behr M, Siegbert R, Elgeti S (2014) Improving the automated optimization of profile extrusion dies by applying appropriate optimization areas and strategies. In: Proceedings of PPS-29: The 29th International Conference of the Polymer Processing Society-Conference Papers, vol 1593, pp 587–591. AIP Publishing
Hu B, Tong K, Niu XP, Pinwill I (2000) Design and optimisation of runner and gating systems for the die casting of thin-walled magnesium telecommunication parts through numerical simulation. J Mater Process Technol 105(1):128–133
Johnson S (2011) The nlopt nonlinear-optimization package. http://ab-initio.mit.edu/nlopt
Jones DR, Perttunen CD, Stuckman BE (1993) Lipschitzian optimization without the lipschitz constant. J Optim Theory Appl 79(1):157–181
Kaelo P, Ali M (2006) Some variants of the controlled random search algorithm for global optimization. J Optim Theory Appl 130(2):253–264
Kong L, She F, Gao W, Nahavandi S, Hodgson P (2008) Integrated optimization system for high pressure die casting processes. J Mater Process Technol 201(1):629–634
Lotfi A (2005) Optimal shape design for metal forming problems by the finite element method. PAMM 5(1):429–430
Michaeli W (2003) Extrusion dies for plastics and rubber. Carl Hanser Verlag GmbH & Co. KG
Michaeli W, Behr M, Nicolai M, Probst M, Elgeti S, Fink B, Windeck C (2009) Towards shape optimization of extrusion dies using finite elements. J Plastics Technol 5:411–427
Michaeli W, Schmitz T, Baranowski T, Fink B (2007) Automatic optimisation of extrusion dies. In: The Polymer Processing Society 23rd Annual Meeting. Bahia do Salvador
Nicolai M (2012) Shape Optimization for Fluids Using T-Splines for Shape Representation and Stabilized Finite Elements for the Fluid Flow Simulations. Verlag Dr Hut
Nóbrega J, Carneiro O, Pinho F, Oliveira P (2004) Flow balancing in extrusion dies for thermoplastic profiles: Part iii: Experimental assessment. Int Polym Process 19(3):225–235
Nocedal J, Wright SJ (2006) Least-Squares Problems. Springer
Pauli L, Behr M, Elgeti S (2013) Towards shape optimization of profile extrusion dies with respect to homogeneous die swell. J Non-Newtonian Fluid Mech 200:79–87
Powell MJ (1994) A direct search optimization method that models the objective and constraint functions by linear interpolation. In: Advances in optimization and numerical analysis, pp 51–67. Springer
Powell MJ (2009) The bobyqa algorithm for bound constrained optimization without derivatives. Cambridge NA Report NA2009/06. University of Cambridge, Cambridge
Queudeville Y, Vroomen U, Bührig-Polaczek A (2014) Modularization methodology for high pressure die casting dies. Int J Adv Manuf Technol 71(9-12):1677–1686
Schlick CM (2009) Industrial Engineering and Ergonomics: Visions, Concepts, Methods and Tools Festschrift in Honor of Professor Holger Luczak. Springer Science & Business Media
Schuh G (2007) Excellence in Production: Festschrift für Univ.-Prof. Dr.-Ing. Dipl.-Wirt. Ing. Dr. techn. hc Dr. oec. hc Walter Eversheim. Apprimus-Verlag
Siegbert R, Elgeti S, Behr M, Kurth K, Windeck C, Hopmann C (2013) Design criteria in numerical design of profile extrusion dies. Key Eng Mater 554:794–800
Siegbert R, Kitschke J, Djelassi H, Behr M, Elgeti S (2014) Comparing optimization algorithms for shape optimization of extrusion dies. PAMM 14(1):789–794
Smith DE (2003) Design sensitivity analysis and optimization for polymer sheet extrusion and mold filling processes. Int J Numer Methods Eng 57(10):1381–1411
Smith DE, Tortorelli D, Tucker CL (1998) Optimal design for polymer extrusion. part i: Sensitivity analysis for nonlinear steady-state systems. Comput Methods Appl Mech Eng 167(3):283–302
Sturm JC (2003) Optimierung von gießtechnik und gussteilen. In: Symposium Simulation in der Produkt-und Prozessentwicklung, vol 5, 5.-7. November 2003, Bremen
Sun Z, Hu H, Chen X (2008) Numerical optimization of gating system parameters for a magnesium alloy casting with multiple performance characteristics. J Mater Process Technol 199(1):256–264
Sussman M, Smereka P, Osher S (1994) A level set approach for computing solutions to incompressible two-phase flow. J Comput Phys 114(1):146–159
Yilmaz O, Gunes H, Kirkkopru K (2014) Optimization of a profile extrusion die for flow balance. Fibers and Polymers 15(4):753–761
Zamora R, Faura F, López J, Hernández J (2007) Experimental verification of numerical predictions for the optimum plunger speed in the slow phase of a high-pressure die casting machine. Int J Adv Manuf Technol 33(3-4):266–276
Zolfaghari A, Behravesh AH, Shakouri E, Soury E (2009) An innovative method of die design and evaluation of flow balance for thermoplastics extrusion profiles. Polym Eng Sci 49(9):1793–1799
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Siegbert, R., Yesildag, N., Frings, M. et al. Individualized production in die-based manufacturing processes using numerical optimization. Int J Adv Manuf Technol 80, 851–858 (2015). https://doi.org/10.1007/s00170-015-7003-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7003-8