COMPUTATIONAL TOOLS FOR DESIGN- DRIVEN SELECTION OF MATERIAL PROCESSING AND MANUFACTURING APPROACHES

ABSTRACT: The current approach to structural design is a trial and error process that uses fixed lookup tables for the material design space. Currently material selection is limited by the database available to designers. ATA Engineering seeks to improve upon the current approach by using novel techniques to deliver computational tools that will identify materials design solutions that are not merely optimum, but also robust to material variability. In this new scheme, material performance parameters are considered to be spatial variables that are adjusted and optimized to meet the design requirements. Such an approach will also enable the analyst to identify design solutions in previously unexplored areas of the material parameter space. This methodology obviates the need to modify any geometry or boundary conditions that the designer had defined to meet the functionality or geometric requirements of the system. To preserve existing design engineering workflows and to allow for easy adoption of the new technology by engineering teams into their design processes, the methods will be implemented within the framework of existing finite element software packages. BENEFIT: This proposed technology seeks to address limitations in the traditional design paradigm by treating the aesthetics and function (geometry and loads) as effectively fixed inputs and defining materials and manufacturing processes as design variables, effectively inverting the typical design approach. This approach will allow the development of better optimized designs and improved performance across a wide variety of products. The envisioned methodology will also aid the definition of performance requirements for new materials an innovative manufacturing techniques. Industries that may be able to take advantage of the proposed technology include gas turbines (jet engines and power generation sets), munitions, remotely piloted vehicles, housing structures, and spacecraft/launch vehicles. Potential customers within those markets include General Electric, Boeing, Lockheed Martin, Solar Turbines, and many others.