Simulatin-Based Design System for Multi-Stage Manufacturing

The feasibility of reducing design time while improving and automating design capabilities will be demonstrated by this Phase I effort. A simulation-based design software tool will be developed that includes a feature-based representation of the part to be manufactured. Feature attributes include shape (dimensions, tolerances, area & volume paramethers), structure (material chemistry, material properties, microstructure, defect state, performance requirements), and surface (finish, contamination, coatings). the material data will be extracted from a comprehensive database of materials based in part on CTC's Atlas of Formability. Unit processes, including forming casting, machining, welding, and heat treatment, will be simulated using simplified process models that are numerically efficient and that address individual part features. These process models will use the material data associated with part features and will be driven by unit process environment variables that are also collected in a database structure. The process models will determine the changes to structure, surface and shape that occur as a consequence of the unit process step. Lastly, optimization methods will be applied to determine the process type and sequence of operations that maximizes performance and qualify while minimizing delivery time and cost. Once an optimum process routing is designed, detailed simulaiton tools including finite element based software can be used to validate the process design.