Modeling and Optimization in Manufacturing

The book provides state-of-the-art knowledge on multiscale modeling and optimization in manufacturing, covering processes such as forming, machining, casting, joining, coating, and additive manufacturing.

Auteur

*Catalin I. Pruncu, PhD, is Research Associate in the Department of Mechanical Engineering at Imperial College in London, United Kingdom. He received his doctorate in Design Mechanics and Biomechanics from Politecnico di Bari in Italy in 2013.*

*Jun Jiang, PhD, is a Lecturer of Mechanics of Materials Division in the Department of Mechanical Engineering at Imperial College London, UK. He received his DPhil from Oxford University in 2013 and joined Imperial College as postdoctoral researcher. Dr. Jiang's research focuses on developing novel manufacturing techniques through the understanding of micro-thermomechanical behaviors for lightweight alloys and solar cells.*

Texte du rabat

Discover the state-of-the-art in multiscale modeling and optimization in manufacturing from two leading voices in the field

Modeling and Optimization in Manufacturing delivers a comprehensive approach to various manufacturing processes and shows readers how multiscale modeling and optimization processes help improve upon them. The book elaborates on the foundations and applications of computational modeling and optimization processes, as well as recent developments in the field. It offers discussions of manufacturing processes, including forming, machining, casting, joining, coating, and additive manufacturing, and how computer simulations have influenced their development.

Examples for each category of manufacturing are provided in the text, and industrial applications are described for the reader. The distinguished authors also provide an insightful perspective on likely future trends and developments in manufacturing modeling and optimization, including the use of large materials databases and machine learning. Readers will also benefit from the inclusion of:

• A thorough introduction to the origins of manufacturing, the history of traditional and advanced manufacturing, and recent progress in manufacturing
• An exploration of advanced manufacturing and the environmental impact and significance of manufacturing
• Practical discussions of the economic importance of advanced manufacturing
• An examination of the sustainability of advanced manufacturing, and developing and future trends in manufacturing Perfect for materials scientists, mechanical engineers, and process engineers, Modeling and Optimization in Manufacturing will also earn a place in the libraries of engineering scientists in industries seeking a one-stop reference on multiscale modeling and optimization in manufacturing.

Résumé

Discover the state-of-the-art in multiscale modeling and optimization in manufacturing from two leading voices in the field

Modeling and Optimization in Manufacturing delivers a comprehensive approach to various manufacturing processes and shows readers how multiscale modeling and optimization processes help improve upon them. The book elaborates on the foundations and applications of computational modeling and optimization processes, as well as recent developments in the field. It offers discussions of manufacturing processes, including forming, machining, casting, joining, coating, and additive manufacturing, and how computer simulations have influenced their development.

Examples for each category of manufacturing are provided in the text, and industrial applications are described for the reader. The distinguished authors also provide an insightful perspective on likely future trends and developments in manufacturing modeling and optimization, including the use of large materials databases and machine learning. Readers will also benefit from the inclusion of:

• A thorough introduction to the origins of manufacturing, the history of traditional and advanced manufacturing, and recent progress in manufacturing
• An exploration of advanced manufacturing and the environmental impact and significance of manufacturing
• Practical discussions of the economic importance of advanced manufacturing
• An examination of the sustainability of advanced manufacturing, and developing and future trends in manufacturing
  Perfect for materials scientists, mechanical engineers, and process engineers, Modeling and Optimization in Manufacturing will also earn a place in the libraries of engineering scientists in industries seeking a one-stop reference on multiscale modeling and optimization in manufacturing.

Contenu

Preface xiii

History of Traditional/Advanced Manufacturing 1
*Esther T. Akinlabi, Michael C. Agarana, and Stephen A. Akinlabi*

1 Introduction 1

2 Progress in Manufacturing 3

3 Overview of Advanced Manufacturing 5

4 Environmental Impact and Significance 6

5 Economic Importance of Advanced Manufacturing 7

6 Sustainability of Advanced Manufacturing 9

7 Trend of Advanced Manufacturing (AM) 10

8 Summary 11

References 12

1 Modeling and Optimization in Manufacturing by Hydroforming and Stamping 13
*Hakim Naceur and Waseem Arif*

1.1 Introduction 13

1.2 Recent Advances in Stamping and Hydroforming Simulation 14

1.2.1 Fast Nonlinear Procedures in Stamping and Hydroforming 16

1.2.1.1 Geometrical Mapping Algorithm 17

1.2.1.2 Radial Length Development Algorithm 17

1.2.1.3 Orthogonal Length Unfolding Algorithm 17

1.2.2 Multistage Inverse Method for Stamping and Hydroforming 20

1.2.2.1 Generation of Intermediate Configurations 21

1.2.2.2 Integration of Stress States 22

1.2.2.3 Procedure for Mapping Fields between Two Configurations 22

1.2.2.4 Application to the Demeri Cylindrical Cup 24

1.2.3 Improved Inverse Method for Stamping and Hydroforming 27

1.2.3.1 Basic Idea 27

1.2.3.2 Deformation Path Prediction 27

1.2.3.3 Consideration of Bending Moments 27

1.2.3.4 Bending and Unbending Problem 29

1.2.3.5 Application to the Square Box of Numisheet93 30

1.3 Optimization of Stamping and Hydroforming Parameters 31

1.3.1 Mathematical Optimization Problem 33

1.3.2 Shape Optimization of the Initial Blank 33

1.3.3 Optimization of Addendum Surfaces of Stamped Parts 34

1.3.4 Optimization of Drawbead Restraining Forces 36

1.3.5 Optimization of Tool Geometry 38

1.3.6 Optimization of Material Parameters 39

1.3.7 Optimization of Hydroforming Process Parameters 41

1.4 Future Outlooks 43

1.5 Conclusions 44

References 45

2 Numerical Simulation Techniques in Casting Process 49
*Qingyan Xu and Cong Yang*

2.1 Introduction 49

2.2 Numerical Models 50

2.2.1 Heat Transfer Model 50

2.2.1.1 Heat Conduction 50

2.2.1.2 Heat Convection 51

2.2.1.3 Heat Radiation 51

2.2.1.4 Heat Conduction Partial Differential Equation 52

2.2.1.5 Finite Difference Method for Solving Heat Transfer Problem 52

2.2.2 Fluid Flow Model 53

2.2.2.1 Continuity Equation 54

2.2.2.2 NavierStokes Equation 54

2.2.2.3 Numerical Algorithms 54

2.2.2.4 Free Surface Track 55

2.2.3 Stress Simulation Model 56

2.2.3.1 Thermal Elastoplastic Model 57

2.2.3.2 Numerical Solution 57

2.2.4 Microstructure Simulation Model 58

2.2.4.1 The Nucleation Model 58

2.2.4.2 The Cellular Automaton (CA) Method 59

2.2.4.3 The Phase-Field Method 59

2.2.5 Initial and Boundary Conditions 61

2.2.5.1 Initial Conditions 61

2.2.5.2 Boundary Conditions 61

2.3 Modeling Casting Process and Optimization 62

2.3.1 Mold Filling Simulation 62

2.3.1.1 Cylinder Head Cover Filling Simulation 62

2.3.1.2 Aircraft Cabin Door Casting Simulation 63

2.3.2 Solidification Simulation 64

2.3.2.1 Comparison Study of DS Solidification Simulation 67

2.3.2.2 Processing Parameter Optimization Using Solidification Simulation 69

2.3.3 Stress Simulation 70

2.3.3.1 Holl…