Innovative techniques for process simulation and cost assessment have been employed during the development of a manufacturing process for an advanced automotive chassis component. The objective is twofold: to achieve cost and time efficiencies while simultaneously enhancing product performance and structural integrity. Sheet metal forming was simulated using finite element-based forming analysis software, incorporating novel tooling strategies. Forming parameters were optimized via a particle swarm optimization algorithm, taking into account practical manufacturing constraints, resulting in a strain distribution improvement of up to 12% with the refined approach implemented in production. A new class of high-strength, thermomechanically processed aluminum alloy blanks was utilized to improve dimensional stability and reduce cycle time. Advanced stamping and assembly techniques were integrated into the production sequence, significantly elevating the level of process automation. The process was evaluated using activity-based costing, enabling the derivation of product costs as an aggregate of all contributory operational activities. Development priorities were realigned based on this analysis to streamline sub-process durations, leading to a more synchronized production workflow. In comparison to conventional manual assembly processes, the semi-automated solution demonstrated quantifiable cost reductions approaching 18%.
Open Access