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The present automotive product development environment is characterised by the customer’s thirst for new, innovative and affordable products. This imposes a shorter Product Development Process (PDP). A healthy concept definition, and control, at the early PDP stages results in successful end products. A key factor of which is an upfront knowledge assessment and integration between the ‘true’ customer’s needs and marketing/finance, product design/engineering and manufacturing functions. The Common workspace in all these functions is considered to be the product model.

Thermal hydroforming process was developed to overcome the problems of forming aluminium alloy sheets or tubes, which are used extensively in the automotive industry for weight reduction and corrosion resistance. FEA simulation was used to predict the thermal hydroforming process and was verified by experimental analysis. Strains of up to 130% were reached during the experiments, which corresponds to five times higher strains than that present in AlMg alloy at room temperatures. The FEA model can be used to assess the feasibility of new components.

This paper is concerned with a relatively new bending technique, known as Free-Bending. Its possibilities to realise geometries with almost arbitrary bending radii, with freely definable bending angles, which can be in several planes make this technique very interesting for an application in the automobile industry, especially in the field of car chassis and space frames. Therefore the paper shows some practical examples of geometries which were investigated with bending tests and examined by means of the finite element method. Furthermore the extended possibilities and the restrictions of this new technology are discussed.

This paper presents the technology and some experiments results of a novel Rapid Prototyping/Tooling/Manufacture (RP/RT/RM) process, Shell Assisted Layer Manufacturing (SALM), which is based on layer manufacturing technology (LMT). The SALM process executes two essential steps to develop one layer of the part. Initially, it develops the outer shell (boundaries) of the particular layer of the part using the Fused Deposition Modelling (FDM) technique and then the shell is filled with UV (Ultraviolet) curable resin. The deposited resin layer is then cured using a UV light source. This procedure is repeated until the complete part is built. The process has the potential to give improved quality, productivity and process speed.

The introduction and evaluation of the simulation tool LS-DYNA in manufacturing process simulation is the basis for a new view in the virtual development chain. The explicit LS-DYNA forming simulation can map complex processes very exactly. One intention is to achieve more accurate computer models with the transfer of the part properties caused by production for subsequent crash and strength calculations. Using case studies a view of the transferable data is analysed to highlight their effects on the part.

The performance of an Electro Chemical Discharge Machining (ECDM) machine, in terms of surface finish and rate of machining is significantly influenced by the performance of the tool position control system, process controller, and the pulse generator. This investigation concentrates on the tool position control system and the paper presents a system identification for the controller design.

Laser Assisted Jet Electrochemical Machining (LAJECM) is a hybrid process which combines electrolyte jet and low power laser beam (375mW) to facilitate material removal. The main purpose of the laser is to enhance dissolution from the workpiece in the specific area giving faster dissolution in axial rather in lateral direction and in result higher dimension precision. Experimental analysis using stainless steel, titanium alloy and high carbon alloy has proved that laser assistance can yield up to 33% higher volumetric rate and up to 65% better dimensional accuracy. It has been also proved that laser enhances current efficiency during the machining process.

This paper presents the pulse classification of the ECDM process using Fuzzy Logic (FL). An Electro Discharge Machining (EDM) machine was modified by incorporating an electrolyte system and by modifying the control system. Gap voltage and working current waveforms were obtained. A fuzzy rule base was designed and simulated to classify pulses. Different ECDM process variables were considered to design the pulse classification rule base. The performances were compared by changing the process variables and by changing rules in the fuzzy rule base. The classification accuracy was measured in the classification system. A quantitative analysis was performed to evaluate the fuzzy pulse classifier with different process variables and with different fuzzy rules for the ECDM machine.

Scroll compressors are a relatively new and advanced type of power equipment. To design and manufacture scroll compressors, however, is not easy for the reasons that their key parts have complex shapes with involute curves. The authors have developed a design approach that can cope with simultaneous design activities concurrently within one single environment. The approach is implemented by using Pro/ENGINEER and Visual C++ programming. The work presented is focused on the integration of Constructive Solid Geometry (CSG) solid modelling, FEM and CAM to effect the design of scroll compressors and with this particular approach a correct and precise solid model can be achieved, which leads to an optimal design in terms of specification adherence, quality, delivery time and cost.