How I have modified my product to make it aesthetically better and cost effective

Old Product

Optimized product

Study and analysis of current Product

Current product is not very appealing, however functionally perfect, since the all tire and vehicle fitment profile/dimensions are within tolerance. There are many way-outs to change the product, however the changes might not contradict with the customer drawing or specification, so that it should meet the critical parameters to avoid any functional defects.

Therefore, the scope of change/modifications is a daunting task, that require full know-how of the product and there should be the calculated impact of change, based on that generate the best possible alternative ideas, like in my case I have just added the best possible shapes to meet the mini. Material input and max. endurance strength to meet the physical test requirements.

Generate Ideas

There are many potential ideas comes out from the studies such as Raw material thickness change, Shape change (wherever allowed), RM grade change. Process these ideas for further screening criteria like, Raw material thickness and grade are in contradiction with the requirements of the drawing and in shape you can only manipulate non-functional shape, since it should not affect any fit and function which might have adverse effect on the mass supplies.

Nevertheless, consider the final one idea and again make alternatives out of that, like I have chosen the shape change idea, the question is how much change is optimum to meet both targets, that is performance and cost effectiveness.

After identify your subject of change, even highly professionals are advised to re-check for any contradiction with in the drawings or specifications.

Prepare designs and calculate the Raw material

Out of alternate ideas, prepare the design of all and calculate the blank size/ raw material size. Which is again an expert task, see the topics blank size calculation of bend parts and raw material calculation of the complicated shapes.

Next step is to validate the calculated material size, either physically or best alternate is the cad geometry with FEA technique, there are software available such as Siemens NX with one step analysis, in brief it requires cad geometry with mid-surface, the thickness and material grade to put separately in input column. Mesh the geometry, the accuracy of your output shape is directly depends upon your mesh quality.

or there is another high end software like ‘Hyperworks’ with one step forming analysis, there is same method, it’s requires more inputs and more professional with more settings and options, thereby the results are more accurate and reliable.

Technology make things easier, eventually you should know how to use it correctly.

The simulation example of the best developed blank option, the simulation was performed with the help of Hyperworks with solid mesh.

Forming Simulation
Apart from the forming simulation, there is one unseen potential failure taken care during design was the material bulging at the corner of bending, which might cause wear/abrasion with the mating part during assembly. It's always easy to understand the basics, but it takes years to find nuances. For more clarity the points are marked in the below image :

Corner Relieving

Make proto samples and validate

Don’t be hastened in decision making, since it’s very crucial step, so proto sample is always the best alternative. Make proto samples – 3 or 4 types to match with your ideas. Compare from every aspect such as Aesthetically by careful self-observation as well as from others perspectives.

From material savings, note the optimum shape with max. utilization.

From Endurance strength, by putting it on the test rigs and verify after physical testing. Never be hastened in decision making, since decision can’t be made on the basis of single test results, so it’s essential to repeat the tests with more specimen to be sure of performance.

Select the best alternative

Now you have a full data/information of the potential rivals, make a clean comparison data in terms of utilization, aesthetics, test results.

Decision making is a crucial step and everyone has its own viewpoint, therefore it’s always better to discuss with your team mates and CFT (cross functional teams) in your organization. The suggestions from everyone are welcome and to be deeply analyzed, however the key decision making is the sole responsibility of the Engineering Team lead.

Experience matters in the final process of decision making, consult your seniors or managers who are enough experienced to guide you about any potential demerits which could remain hidden from you. In some cases, you can offer it to your customer as a better rival/alternative of your existing products with all the evidence of validation and request him to check the fitment jointly along with final sign off to reduce any final risk.