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Research Papers: Design for Manufacture and the Life Cycle

Additive Manufacturing-Enabled Part Count Reduction: A Lifecycle Perspective

[+] Author and Article Information
Sheng Yang

Department of Mechanical Engineering,
McGill University,
Montreal, QC H3A 0C3, Canada
e-mail: sheng.yang@mail.mcgill.ca

Yaoyao Fiona Zhao

Department of Mechanical Engineering,
McGill University,
Montreal, QC H3A 0C3, Canada
e-mail: yaoyao.zhao@mcgill.ca

1Corresponding author.

Contributed by the Design for Manufacturing Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received January 29, 2017; final manuscript received December 19, 2017; published online January 25, 2018. Assoc. Editor: Timothy W. Simpson.

J. Mech. Des 140(3), 031702 (Jan 25, 2018) (12 pages) Paper No: MD-17-1068; doi: 10.1115/1.4038922 History: Received January 29, 2017; Revised December 19, 2017

Part count reduction (PCR) is one of the typical motivations for using additive manufacturing (AM) processes. However, the implications and trade-offs of employing AM for PCR are not well understood. The deficits are mainly reflected in two aspects: (1) lifecycle-effect analysis of PCR is rare and scattered; (2) current PCR rules lack full consideration of AM capabilities and constraints. To fill these gaps, this paper first summarizes the main effect of general PCR (G-PCR) on lifecycle activities to make designers aware of potential benefits and risks and discusses in a point-to-point fashion the new opportunities and challenges presented by AM-enabled PCR (AM-PCR). Second, a new set of design rules and principles are proposed to support potential candidate detection for AM-PCR. Third, a dual-level screening and refinement design framework is presented aiming at finding the optimal combination of AM-PCR candidates. In this framework, the first level down-samples combinatory space based on the proposed new rules while the second one exhausts and refines each feasible solution via design optimization. A case study of a motorcycle steering assembly is considered to demonstrate the effectiveness of the proposed design rules and framework. In the end, possible challenges and limitations of the presented design framework are discussed.

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Topics: Manufacturing , Design
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Figures

Grahic Jump Location
Fig. 1

Interrelation between function, component, architecture, and material

Grahic Jump Location
Fig. 2

Proposed dual-step screening and refinement design framework

Grahic Jump Location
Fig. 3

Product and function view of a motorcycle steering assembly: (a) product view and (b) function–function carrier view

Grahic Jump Location
Fig. 4

Level 1: screening process: (a) functional adjacency, (b) modularization, (c) intramodule: standardization, (d) intramodule: relative motion, (e) intermodule: feasibility check, and (f) final solution

Grahic Jump Location
Fig. 5

Hand draft of a consolidated design solution

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