The main design activity in engineering practice is to adapt existing designs or to create variants of existing products to new demands, which require a robust model against both parametric and topological changes. To design such a kind of model becomes a big challenge, especially in the development of structural components due to the number of load application points, variable load cases and restrictions from manufacturing technologies. Thus, the generative parametric design approach is applied to generating high dynamic product models, allowing them to be adjusted for changes feasibly.

This article describes an approach for designing knowledge based Computer Aided Design (CAD) models to represent the complete solution space of the Tailored Forming process chain by depicting the production stages of a component. The aim is to use this knowledge base to determine during the product development process whether the desired component can be manufactured with the available equipment, even if the design engineer does not have the necessary expert knowledge. In addition to the model structure, the implementation of the manufacturing restrictions and the dependencies between the different production stages are shown. The procedure is described using the newly developed tailored forming process chain as an example.

The use of multi-material forming components makes it possible to produce components adapted to the respective requirements, which have advantages over mono-material components. The necessary consideration of an additional material increases the possible degrees of freedom in product and manufacturing process development. As a result, development becomes more complex and special expert knowledge is required. To counteract this, computer-aided engineering environments with knowledge-based tools are increasingly used. This article describes a computer-aided engineering environment (CAEE) that can be used to design hybrid forming components that are produced by tailored forming, a process chain developed in the Collaborative Research Center (CRC) 1153. The CAEE consists of a knowledge base, in which the knowledge necessary for the design of tailored forming parts, including manufacturer restrictions, is stored and made available. For the generation of rough and detailed design and for elaboration the following methods are used. The topology optimization method, Interfacial Zone Evolutionary Optimization (IZEO), which determines the material distribution. The design of optimized joining zone geometries, by robust design. The elaboration of the components by means of highly flexible computer-aided design (CAD) models, which are built according to the generative parametric design approach (GPDA).

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