Integrated Strength and Manufacturing Process Design Using a Shape Optimization Approach

1990 ◽  
Author(s):  
Ramana V. Grandhi ◽  
Sesha C. Modukuru ◽  
James C. Malas
Keyword(s):  
Process Design ◽  
Process Simulation ◽  
Manufacturing Process ◽  
Integrated Design ◽  
Strength Properties ◽  
Turbine Disk ◽  
Optimization Approach ◽  
Forging Process ◽  
Simultaneous Design ◽  
Simplified Analysis

Abstract This paper considers a simultaneous design of product and manufacturing process. The product requirements include strength properties, whereas the manufacturing process goals include cost, quality, and microstructure to produce defect-free parts on a repeatable basis. The concept is demonstrated by designing a turbine disk manufactured using a forging process. A simplified analysis is used in forging process simulation. Formulation of the integrated design problem is emphasized.

Integrated Strength and Manufacturing Process Design Using a Shape Optimization Approach

1993 ◽  
Vol 115 (1) ◽  
pp. 125-131 ◽  
Author(s):  
R. V. Grandhi ◽  
S. C. Modukuru ◽  
J. C. Malas
Keyword(s):  
Manufacturing Process ◽  
Manufacturing Industry ◽  
Integrated Approach ◽  
Strength Properties ◽  
Manufacturing Cost ◽  
Optimization Approach ◽  
Simultaneous Design ◽  
Development Cycle ◽  
Design And Manufacturing ◽  
Product And Process

Intense competition in the manufacturing industry is forcing major changes in cost reduction in every step of the product development cycle starting from the design conception through production. One technique to reduce manufacturing cost is to employ simultaneous engineering between design and manufacturing using sensitivity analysis and iterative techniques. This integrated approach allows those decisions that significantly affect the product and process designs to be made more intelligently up-front. This paper considers a simultaneous design of product and manufacturing process. The product requirements include strength properties, whereas the manufacturing process goals include cost, quality, and microstructure to produce defect-free parts on a repeatable basis. The concept is demonstrated by designing a turbine disk manufactured using a forging process.

Isothermal forging process design for spray-formed FGH95 superalloy turbine disk based on numerical simulation

Rare Metals ◽  
2013 ◽  
Vol 32 (4) ◽  
pp. 347-353 ◽  
Author(s):  
Biao Guo ◽  
Chuan-Sui Sun ◽  
Sui-Cai Zhang ◽  
Chang-Chun Ge
Keyword(s):  
Numerical Simulation ◽  
Process Design ◽  
Turbine Disk ◽  
Isothermal Forging ◽  
Forging Process ◽  
Fgh95 Superalloy

Simplified Method of Resin Infusion Process Simulation on Example of Formula Student Lightweight Components

2016 ◽  
Vol 251 ◽  
pp. 41-46
Author(s):  
Maciej Wnuk ◽  
Artur Iluk
Keyword(s):  
Finite Element ◽  
Process Design ◽  
Process Simulation ◽  
Cost Ratio ◽  
Main Difficulty ◽  
Resin Infusion ◽  
Excellent Quality ◽  
Expensive Equipment ◽  
Simplified Method ◽  
Very High

In the production of lightweight composite parts, resin infusion is the leading technology due to its excellent quality-to-cost ratio [1], [2]. Not only is there no need to use expensive equipment such as autoclaves, but the resulting fiber to resin ratio is very high, which makes parts very stiff, strong, and lightweight [3], [4]. Other advantages include a glossy surface and a structure that free of macro-pores, provided when the process is well prepared. The equipment used in this process allows one to manufacture part in virtually any size and shape [5]. The main difficulty is to design resin feed lines in way that will saturate fabrics until the resin gels. To facilitate this process design finite element codes can be used to simulate the flow of resin during infusion [6].

Study on a Green Manufacturing Process Design System

2013 ◽  
Vol 397-400 ◽  
pp. 57-61
Author(s):  
Dong Jie Zhong
Keyword(s):  
Process Design ◽  
Manufacturing Process ◽  
Design Principle ◽  
Green Manufacturing ◽  
Design System ◽  
Operation Flow

Green manufacturing process is a key segment to guarantee green degree of products manufacturing course. In this paper, a kind of design system is presented by analyzing the function demand of the design system for green manufacturing process and then the modules which constituent the design system are analyzed in detail. Moreover, according to the design principle and the estimate indexes of green manufacturing process, the operation flow of the design system is introduced.

Computer Aided Cold Forging Process Design: Determination of Machine Setting Conditions

CIRP Annals ◽  
1985 ◽  
Vol 34 (1) ◽  
pp. 245-248 ◽  
Author(s):  
P. Bariani ◽  
W.A. Knight ◽  
F. Jovane
Keyword(s):  
Process Design ◽  
Cold Forging ◽  
Forging Process ◽  
Computer Aided ◽  
Machine Setting

ACHIEVING REALISTIC TOW FIBER VOLUME FRACTIONS IN TEXTILE COMPOSITE MODELS BY INDUCING FIBER ENTANGLEMENT

2021 ◽  
Author(s):  
GEORGE BARLOW ◽  
MATHEW SCHEY ◽  
SCOTT STAPLETON
Keyword(s):  
Process Simulation ◽  
Manufacturing Process ◽  
Fiber Bundle ◽  
Fiber Volume Fraction ◽  
Volume Fraction ◽  
Simulation Method ◽  
Textile Composite ◽  
Compression Pressure ◽  
Fiber Volume ◽  
Composite Models

Modeling composites can be an effective way to understand how a part will perform without requiring the destruction of costly specimens. By combining artificial fiber entanglement with manufacturing process simulation, a method was developed to create fiber bundle models using entanglement to control the fiber volume fraction. This fiber entanglement generation uses three parameters, probability of swapping (p_(r_S )), swapping radius standard deviation (r_(σ_S )), and the swapping plane spacing (l_S), to control the amount of entanglement within the fiber bundle. A parametric study was conducted and found that the more entanglement within a fiber bundle, the more compression mold pressure required to compact the fiber bundle to the same fiber volume fraction as that required for a less entangled bundle. This artificial fiber entanglement and manufacturing process simulation method for creating fiber bundles shows the potential to be able to create bundles with controlled final volume fraction using a desired mold compression pressure.

Integrating Product Design With Manufacturing Process Design Using the Robust Concept Exploration Method

1996 ◽  
Author(s):  
Jesse D. Peplinski ◽  
Janet K. Allen ◽  
Farrokh Mistree
Keyword(s):  
Product Design ◽  
Process Design ◽  
Manufacturing Process ◽  
Response Surfaces ◽  
Production Costs ◽  
Early Stages ◽  
Trade Offs ◽  
Development Costs ◽  
Concept Exploration ◽  
Product And Process

Abstract How can the manufacturability of different product design alternatives be evaluated efficiently during the early stages of concept exploration? The benefits of such integrated product and manufacturing process design are widely recognized and include faster time to market, reduced development costs and production costs, and increased product quality. To reap these benefits fully, however, one must examine product/process trade-offs and cost/schedule/performance trade-offs in the early stages of design. Evaluating production cost and lead time requires detailed simulation or other analysis packages which 1) would be computationally expensive to run for every alternative, and 2) require detailed information that may or may not be available in these early design stages. Our approach is to generate response surfaces that serve as approximations to the analyses packages and use these approximations to identify robust regions of the design space for further exploration. In this paper we present a method for robust product and process exploration and illustrate this method using a simplified example of a machining center processing a single component. We close by discussing the implications of this work for manufacturing outsourcing, designing robust supplier chains, and ultimately designing the manufacturing enterprise itself.

Process design for maintainability: an optimization approach

2000 ◽  
Vol 24 (2-7) ◽  
pp. 203-208 ◽  
Author(s):  
Efstratios N. Pistikopoulos ◽  
Constantinos G. Vassiliadis ◽  
Lazaros G. Papageorgiou
Keyword(s):  
Process Design ◽  
Optimization Approach ◽  
Design For Maintainability
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