Considering Manufacturing in Functional Modelling - Case Study on Combination of Simulation-Driven Design with Design-for-Manufacture

In engineering design, function fulfilment is the raison d'être of a product. However, economic boundary conditions have to be taken into consideration as well to enable marketability of the product. In this paper, a case study is presented, where function-based engineering using the Simulation-Driven Design is linked with Design-for-Manufacture as an example for economic design through qualitative modelling. The qualitative modelling with the Contact and Channel Approach aims to support the integrated consideration of functional requirements and manufacturing boundary conditions. The linked approaches are applied in the development of a test rig for hammer drills. It shows how Design-for-Manufacture can be considered early in conceptual decisions in embodiment design by separating functional embodiment and residual structure through qualitative modelling. The freeze-unfreeze strategy is presented as a possibility to identify potential for Design-for-Manufacture to meet economic boundary conditions in conceptual design without reducing the functionality of the system. Further research possibilities regarding qualitative modelling to support functional and economic design are uncovered.