Conceptual design, manufacturability evaluation and preliminary process planning using function-form relationships in stamped metal parts

A large number of design decisions are made during the conceptual design of a part. However, there are few representation and reasoning tools for decision support during conceptual design. The conceptual design stage is characterized by a lack of complete geometric information. Existing geometric modelers require complete geometric information, while a functional reasoning methodology using a <verb, noun > representation is typically too terse. In this paper, we present a new representation called sketching abstraction for conceptual design, using the function-form relations in a design. The functionally critical part of the geometry is presented using a set of functional features, while the rest of the geometry is abstracted as a set of linkages. Part functionality is correlated with the sketching abstraction using data structures called function-form matrices. The sketching abstraction is annotated using a set of primitives, and a set of grammar rules are used to extract canonical relationships between the functional features. The sketching abstraction can be used for extracting designs that are geometrically dissimilar but functionally similar, thus providing the designer with ideas for design alternatives. The sketching abstraction can also be used to carry out domain-dependent manufacturability evaluation checks. A further use of sketching abstractions is to initiate the development of a process plan for manufacturing. Sketching abstractions are related to the solid model of a part. Thus, this representation provides a link between pure functional and pure geometric representations. The domain of application is stamped metal parts. We present the part functionality and the features used in this domain. We also illustrate the use of sketching abstractions for conceptual design, manufacturability evaluation and preliminary process planning.