Since the revolutionary invention of conveyor-belt production by Henry Ford in 1913, market player mainly evolved a unique selling point through E-Mobility. Mega-Casting promises simplification automotive system using large-format high-pressure die-cast (HPDC) aluminium structural components car body. Through 35 cross-industry expert interviews system, paper's study has aim to (1) present first time analysis disrupting concept. Based on grounded theory and coding methodology, economical,...

Due to various trends, such as e-mobility, a long-term change in the automotive value creation structure is foreseeable. Shorter development cycles demand early prototypes and cause more changes. Currently, there no cost-effective production process for originally deep drawn sheet metal parts series quality at small volumes. In this paper, application of additively manufactured functional elements drawing tools investigated. Besides first concept tools, experimental test are described analyzed.

In relation to the fourth industrial revolution, traditional manufacturing methods cannot serve flexibility demands related mass customization and small series production. Rapid tooling provided by generative has been suggested recently in context of metal forming. Due high loads applied during processes such tooling, a purposeful mechanical description additively manufactured (AM) materials is crucial. Until now, comprehensive characterization approach for AM polymers required allow...

Asymmetric Incremental Sheet Forming (AISF) is a process for the flexible production of sheet metal parts. In AISF, part obtained as sum localized plastic deformations produced by simple forming tool that, in most configurations, moves under CNC control. Flexible processes with low tooling effort like AISF are suitable sectors small lot sizes but premium products, e.g. aviation and automotive sector. Four main limits restrict range application its take-up industry. These are: (i) material...

High strength steels enable new solutions for weight optimized car bodies without sacrificing crash safety. However, cold forming of these is limited due to the need high press capacity, increased tool wear, and limitations in possible geometries. One can compensate drawbacks by local heat treatment blanks. In high-deformation areas material reduced plasticity diode laser irradiation. Local with radiation could also yield key benefits applicability hardened parts. not desired all over part....

Topology optimisation (TO) and Laser Powder Bed Fusion (LPBF) for the manufacturing of welding jigs used in automotive body shops shows high potential regarding material efficiency, weight reduction, integration additional functions into metal LPBF jig elements. For conventional series production, steel or aluminium elements are manufactured by using water jet cutting machining processes, such as milling, drilling, turning. To determine economic efficiency topological optimised elements,...

The goal of this project is to determine the efficiency 3D printed welding jigs in pre-series body shops. design these and how they function compared conventional jig systems analyzed. Additive manufactured parts possess advantage easier production complex which would serve purpose designing custom for different intricate detailed with odd orientations. While machining can be costly, printing provides precision as well reduces costs setup time since are designed their specific application.

While deep drawing of sheet metals is economical at high volumes, it can be very costly for manufacturing prototypes, mainly due to tooling costs. Additively manufactured polymer tools have the potential more cost-efficient small series, but they are softer and thus less resilient than conventional steel tools. This work aimed study dimensional precision such using a standard cup geometry. Tools were printed with FFF two different materials, PLA CF-PA. A test series 20 parts was drawn from...

Product variants and engineering change requests challenge the automotive body shop make flexible production systems necessary to sustain competitively. Component-integrated fixture feature (CFF) can enable by reducing specific jig technology integrating their functions in components be joined. This research paper presents digital twin simulation modelling of a fixtureless concept coupling physical cell virtual environment. The effect CFF on welding process, equipment, integration planning,...

Trends in the automotive industry such as e-mobility require faster development approaches. This is especially relevant for plastic parts because of high number vehicles. Polymer-based additive manufacturing injection molds cheaper and than conventional tooling. Therefore, polymer allow to be produced validated at an early stage. paper provides a proof concept with slides undercuts. The investigation consists design experimental study including calculation process capability.

The automotive industry is currently facing increased pressure to innovate by developing and producing several drive concepts in parallel. This results demands on product development. Rapid, cost-reduced implementation of tool changes during the development process becoming a decisive advantage an increasingly competitive market. Other players are also entering vehicle development, which digital, dynamic, flexible close customer. increasing number small medium-sized series trend towards mass...

The increasing variety of models with simultaneously lower and more volatile quantities in the demanding environment automotive engineering calls for flexible production systems. Considering an automobile process, body shop can be characterized as particularly inflexible. This results from highly product-specific automated technical solutions such rigid fixture systems grippers, commonly used to fulfil geometrical requirements parts respective system. Therefore, several approaches have been...

The automotive body shop meets numerous new requirements in the context of electric mobility. Various production concepts currently exist to meet these requirements. Particularly, flexible solutions are gaining importance. However, actual effects on unclear. aim this paper is therefore develop an evaluation framework for flexibility shop. First, general and specific innovative derived characteristics identified. Subsequently, a correlation analysis between lays basis conception validation...

Fixture and clamping technologies of automated production lines for structural components in vehicles turned out as the main cost driver with up to 29 % total investment costs equipment. Additionally, they limit product flexibility variants change requests during development process. Flexible concepts, like jigless joining component-integrated jig features (CJF) might be a promising approach reduce component specific technology. Technical well economical aspects are investigated on low-cost...

Additive manufacturing technology develops very dynamically in terms of new processes, materials and areas application. Cost intensive post processing, especially removal support structures is one big challenge material extrusion (ME) processes drives development machine designs like 5-axis printers. Currently, time manual programming code necessary order to slice parts for multi-axis printing. This paper deals with an experimental study state-of-the-art 3D-printers developing a...

This paper presents a model to approach the selection of temperature control measures for polymer-made additive injection molds. Such molds are used in manufacturing close-to-series prototype, but still limited small volumes, low production rates and standard polymer materials. Measures can increase applicability those The allow maintaining optimal process parameters desired application. aims summarise possible measures, their current state research argues comprehensive supporting process.

Kurzfassung Elektrofahrzeuge weisen im Vergleich zu konventionell angetriebenen Fahrzeugen aufgrund fehlender Erfahrungswerte sowie neuer Technologien während des Markthochlaufs hohe Industrialisierungskosten auf. In einem gemeinsamen Forschungsprojekt zwischen den E-Fahrzeugherstellern e.GO Mobile AG und StreetScooter GmbH, der Laser Bearbeitungs- Beratungszentrum GmbH (LBBZ), TRUMPF Laser- Systemtechnik als System- Fügespezialisten, dem Lehrgebiet Füge- Trenntechnik FH Aachen Lehrstuhl...

Surface properties of injection molded parts have a strong effect on the visual and haptic perception by customers. Especially for automotive interior parts, grained surfaces can often be found. In conventional tooling, graining requires separate process steps. This makes realization prototype very complex. By additive manufacturing molds in it is possible to print micro structures into mold surface one printing operation. An with four different varying depth distance was designed additively...