stances. To offset these added costs, more advanced and cost-effective joining and forming operations must be developed. For example, in the automotive industry the adoption of high-strength aluminum for body parts may increase product cost in an effort to meet lightweighting demands. A gap with current joining and forming technolo- gies for aluminum is the need to improve process quality and consistency to reduce scrap rates, which will assist in reducing production costs.
Reduced Time to Market The product development cycle continues to shrink in many industries. This is in part being driven by global competition as well as an increased benefit for being “first to market” with a new product or a new genera- tion of an existing product. The automotive industry is a good example where the time from concept design to showroom availability is ap- proximately one-half what it
approaches are needed along with development of rapid prototyping tools.
Improved Energy Efficiency and Environmental Effects The growth of “green” manufacturing to reduce energy demands in the manufacturing of goods along with reduced environmental effects continues to gain importance. Accom- plishing these goals may also reduce manufacturing costs in some cases. Environmental considerations include the ability to recycle manufactured goods at the end of their useful service life and as well as reduce environmental “emissions” during the life of the product. Reduced CO2
emissions from
Streamlined material qualification approaches are needed along with development of rapid prototyping tools.
was in the 1990s. Likewise, in the oil & gas industry, it was common to require about 8 to 10 years to design, fabricate, install and commission large off-shore oil platforms, often at a cost of several billion dollars. Today, the desire is to accomplish these tasks in as little as five years with the benefit being significantly reduced upfront costs to get the platform operational as well as the ability to produce profits much sooner as the platform begins producing oil and/or gas much earlier. As is well known, the product develop- ment cycle in the electronics industry continues to shrink by orders of magnitude by comparison. To accomplish these goals, advancements in complex computer modeling codes is required to streamline product design tasks and simulate performance under service conditions to reduce time-consuming testing protocols used in many industries. The implementation of “Big Data” to share manufactur- ing related data throughout the manufacturing process will improve efficiency in operations and reduce scrap and rework. Development of extensive material property databases is needed to effectively provide critical data to designers and engineers on material interactions and per- formance expectations. Streamlined material qualification
cars and trucks is a clear example. More environmentally friendly batteries and reductions in heavy metal releases from power plant and many pet- rochemical plant operations are additional needs. Not as readily recognized is the growing desire to reduce wa- ter requirements for certain manufacturing activities in consideration of the increas-
ing demands on diminishing freshwater supplies in many areas. Certainly the cost of electricity and water is increasing for consumers and this trend also impacts manufacturers.
Next Steps
EWI and its project partners will be completing the road- map on advanced joining and forming technologies by the middle of 2016. Follow-on funding will be sought to allow the execution of roadmap priorities. EWI plans to establish and manage a consortium of research and industrial part- ners to oversee the execution of roadmap projects and the deployment of compelling next-generation technologies to the manufacturing floor. In addition, workforce development initiatives will be pursued to address the shrinking technical workforce in many industries. Successful implementation of the roadmap priorities will enhance the competitive position of US manufacturers while reinvigorating the manufacturing base, which is critical to the overall strength and robustness of the US economy.
Hyunok Kim and Tom McGaughy are providing leadership for SME’s Forming & Fabricating Technical Community (FFC).
21 — Motorized Vehicle Manufacturing 2015
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