This dissertation presents a scientific based approach for the analysis of folded
sheet metal products. Such analysis initializes the examination in terms of topological
exploration using set of graph modeling and traversal algorithms. The geometrical
validity and optimization are followed by utilizing boundary representation and
overlapping detection during a geometrical analysis stage, in this phase the optimization
metrics are established to evaluate the unfolded sheet metal design in terms of its
manufacturability and cost parameters, such as nesting efficiency, total welding cost,
bend lines orientation, and maximum part extent, which aides in handling purposes.
The proposed approach evaluates the design in terms of the stressed-based
behavior to indicate initial stress performance by utilizing a structural matrix analysis
while developing modification factors for the stiffness matrix to cope with the stressbased
differences of the diverse flat pattern designs. The outcome from the stressed-based
ranking study is mainly the axial stresses as exerted on each element of folded geometry;
this knowledge leads to initial optimizing the flat pattern in terms of its stress-based
behavior. Furthermore, the sheet folding can also find application in composites
manufacturing. Thus, this dissertation optimizes fiber orientation based on the elasticity
theory principles, and the best fiber alignment for a flat pattern is determined under
certain stresses along with the peel shear on adhesively bonded edges.
This study also explores the implementation of the fold forming process within
the automotive production lines. This is done using a tool that adopts Quality Function Deployment (QFD) principle and Analytical Hierarchy Process (AHP) methodology to
structure the reasoning logic for design decisions. Moreover, the proposed tool
accumulates all the knowledge for specific production line and parts design inside an
interactive knowledge base. Thus, the system is knowledge-based oriented and exhibits
the ability to address design problems as changes occur to the product or the
manufacturing process options. Additionally, this technique offers two knowledge bases;
the first holds the production requirements and their correlations to essential process
attributes, while the second contains available manufacturing processes options and their
characteristics to satisfy the needs to fabricate Body in White (BiW) panels. Lastly, the
dissertation showcases the developed tools and mathematics using several case studies to
verify the developed system’s functionality and merits. The results demonstrate the
feasibility of the developed methodology in designing sheet metal products via folding.