The key objectives of this research were to develop an integrated design and analysis methodology for sheet-metal product development based on agent-based technology, feature-based design, optimization and finite element analysis techniques, and to study the performance of prototype systems developed based on such a methodology. To achieve the research objectives, an agent-based framework was proposed for integrating and coordinating activities of participants involved in sheet-metal product development based on the investigation of the industrial requirements and the procedures of the development of sheet-metal products. Prototype systems were developed based on the proposed framework to answer research problems outlined for the design and implementation of agent-based systems, such as agent encapsulation, system architecture, agent communication and agent coordination. The performance of such prototype systems demonstrates that communication and coordination among domain agents can facilitate product development and reduce product cost. An agent-based optimization approach based on an "A-Teams" approach (Talukdar et al, 1996) was proposed for process optimization in the tooling design stage to combine the utilization of the traditional optimization techniques used to solve sheet-metal forming problems and agent-based approaches. Three test cases were used of varying complexity from a rectangular cup to the NUMISHEET'99 automobile front door panel simulation benchmark for the determination of optimal drawbead restraining forces and blankholder forces when designing draw dies for stamped parts. A network of software agents, each implementing a different numerical optimization technique, was used in combination with metal forming simulation software to optimize process variables. It was found that the performance of each agent (and optimization technique) depended strongly on the complexity of the problem. For a given amount of computational effort, a network of collaborating agents using different optimization techniques always outperformed agents using a single technique in terms of both the best solution found and the variance of the collection of best solutions. To provide guidance for the design and implementation of real applications, static and dynamic attributes and metrics of such agent-based collaborative systems, which can be evaluated in the preliminary system design stage and the system implementation stage, were proposed to study the impact of system architectures and coordination strategies on system performance. In addition, real-time system performance was statistically studied based on the data collected by the visualiser agent generated with the agent building toolkit. The results of case studies for system performance evaluation demonstrate the applicability of evaluation strategies proposed and can be used as a reference model for performance and scalability analysis on agent-based sheet-metal product development systems. The proposed evaluation strategies are applicable to general applications for product development by taking into consideration other performance indicators. / Thesis / Doctor of Philosophy (PhD)

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