A Case‐Based Reasoning Approach to Model Manufacturing Constraints for Impact Extrusion

This study introduces a hybrid modeling approach for manufacturing processes, combining a constraint‐based process model with case‐based reasoning (CBR). The constraint‐based model formalizes geometric transformations, material behaviors, and manufacturing constraints through explicit mathematical expressions. CBR integrates knowledge from simulations and experimental data, enabling the representation of complex and nonlinear relationships without full formalization. The approach supports manufacturability analyses during product design by creating an adaptive modeling environment. Application to a hybrid extrusion process demonstrates its effectiveness in modeling the deformation and stress behavior of the joining zone in multimaterial components. Key results reveal that counter pressure reduces tensile stresses in the joining zone, improving bond integrity, while changes in shoulder angle and tapering influence geometry and stress distribution. Simulation data integrated into CBR identifies similar scenarios and predicts manufacturability for new configurations. This method enhances the alignment of design decisions with manufacturing constraints, reducing development time and improving product quality. Future work aims to extend this approach to additional processes in the tailored forming chain, providing a comprehensive framework for manufacturing knowledge.