Individualized production in die-based manufacturing processes using numerical optimization

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.