overview
industry and research leaders. A goal of the roadmap is to leverage existing funding sources and regional economic development structures to begin to develop and implement tangible solutions for manufacturers of all sizes.
Emerging Challenges Materials joining and forming technolo-
gies are closely related in terms of their applications, users, technical fundamentals and emerging challenges. Production lines often involve both forming and joining pro- cesses. Design optimization often involves assessing tradeoffs between forming and joining options. The approach used to form a component can have a signifi cant impact on subsequent joining processes and vice versa. The two areas also require similar technical understanding of mate- rial science, heat transfer, solid mechanics and control of process equipment. Several joining processes use forming of materials to produce joints, including forge welding, clinching, self-piercing riveting and magnetic-pulse welding. Joining and forming technologies are also rapidly evolving in response to increasing product performance requirements, the introduction of many new materials, and relentless internation- al competitive pressure to reduce manufacturing costs. Joining and forming technologies that did not even exist 20 years ago are being broadly applied today.
The US manufacturing industry faces numerous technical challenges, which necessitate continued rapid innovation in joining and forming technologies, including: • Application of new materials to optimize product perfor- mance and cost. This requires new manufacturing pro- cesses to form and join a wide range of high-performance materials and material combinations.
• Increased use of simulation to optimize products in order to satisfy increasing design requirements while reducing the need for physical prototypes. This requires integrated computational materials engineering (ICME) approaches to predict the interaction of materials and process conditions on the overall product performance.
Forming simulation of an automotive lightweight aluminum door part using PAM-STAMP software.
• Drive to reduce manufacturing costs and increase product reliability by ensuring 100% first-time quality. This requires more robust manufacturing processes in combination with new real-time process monitoring and control approaches to detect and correct nonconformances.
• Need to develop new test methods, baseline data, and standards for many new manufacturing process varia- tions. This requires both analytical models and empiri- cal test data to understand the interaction of processes and material variables on products, devising appropriate tests, and updating codes and standards to reflect these new approaches.
• Requirements to develop more agile, highly automated manufacturing operations which can produce a wide variety of components in small batches (high mix, low volume). This requires flexible tooling approaches and automation sys- tems which can sense manufacturing variations and adapt forming and joining processes to compensate on the fly.
• Desire to employ near-net-shape processes to produce complex parts with fewer operations. This requires new de-
18 — Motorized Vehicle Manufacturing 2015
Courtesy EWI
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64 |
Page 65 |
Page 66 |
Page 67 |
Page 68 |
Page 69 |
Page 70 |
Page 71 |
Page 72 |
Page 73 |
Page 74 |
Page 75 |
Page 76 |
Page 77 |
Page 78 |
Page 79 |
Page 80 |
Page 81 |
Page 82 |
Page 83 |
Page 84 |
Page 85 |
Page 86 |
Page 87 |
Page 88 |
Page 89 |
Page 90 |
Page 91 |
Page 92 |
Page 93 |
Page 94 |
Page 95 |
Page 96 |
Page 97 |
Page 98 |
Page 99 |
Page 100 |
Page 101 |
Page 102 |
Page 103 |
Page 104 |
Page 105 |
Page 106 |
Page 107 |
Page 108 |
Page 109 |
Page 110 |
Page 111 |
Page 112 |
Page 113 |
Page 114 |
Page 115 |
Page 116 |
Page 117 |
Page 118 |
Page 119 |
Page 120 |
Page 121 |
Page 122 |
Page 123 |
Page 124 |
Page 125 |
Page 126 |
Page 127 |
Page 128 |
Page 129 |
Page 130 |
Page 131 |
Page 132 |
Page 133 |
Page 134 |
Page 135 |
Page 136 |
Page 137 |
Page 138 |
Page 139 |
Page 140 |
Page 141 |
Page 142 |
Page 143 |
Page 144 |
Page 145 |
Page 146 |
Page 147 |
Page 148 |
Page 149 |
Page 150 |
Page 151 |
Page 152 |
Page 153 |
Page 154 |
Page 155 |
Page 156 |
Page 157 |
Page 158 |
Page 159 |
Page 160 |
Page 161 |
Page 162 |
Page 163 |
Page 164 |
Page 165 |
Page 166 |
Page 167 |
Page 168 |
Page 169 |
Page 170 |
Page 171 |
Page 172 |
Page 173 |
Page 174 |
Page 175 |
Page 176 |
Page 177 |
Page 178 |
Page 179 |
Page 180 |
Page 181 |
Page 182 |
Page 183 |
Page 184 |
Page 185 |
Page 186 |
Page 187 |
Page 188 |
Page 189 |
Page 190 |
Page 191 |
Page 192 |
Page 193 |
Page 194 |
Page 195 |
Page 196 |
Page 197 |
Page 198 |
Page 199 |
Page 200 |
Page 201 |
Page 202 |
Page 203 |
Page 204 |
Page 205 |
Page 206 |
Page 207 |
Page 208