A novel approach for integrating the optimization of the lifetime and cost of manufacturing of a new product during the design phase

Maximum lifetime and minimum manufacturing cost for new products are the primary goals of companies for competitiveness. These two objectives are contradictory and the geometric dimensions of the products directly control them. In addition, the earlier design errors of new products are predicted, the easier and more inexpensive their rectification becomes. To achieve these objectives, we propose in this article a novel model that makes it possible to solve the problem of optimizing the lifespan and the manufacturing cost of new products during the phase of their design. The prediction of the life of the products is carried out by an energy damage method implemented on the finite element (FE) calculation by using the ABAQUS software. The manufacturing cost prediction is carried out by applying the ABC cost estimation analytical method. In addition, the optimization problem is solved by the method of genetic algorithms. The proposed model can be successfully applied for the optimization of new mechanical products made by subtractive manufacturing. The products that mostly benefits from this model are those used in machines and in the automotive or aeronautic fields. The proposed approach can be directly used by the designer for an optimal preliminary design of new products whose manufacture is done by the same company or subcontracted entirely or partially by other companies.