SBIR-STTR Award

Austral Engineering and Software, Inc. proposes to develop a computer platform for simulation-and-optimization-based design of multiple-stage manufacturing processes. Phase I will use metal forming processes to demonstrate feasibility of embedding analytical models of basic transport phenomena into design models that include geometric, microstructure, and processing features. Each stage of a metal forming process will be simulated by a computer process and visualized in a computer window. By connecting these virtual metal forming stages, a simulation of the whole manufacturing process will be formed. This will allow the user to obtain information about interdependencies among manufacturing stages. Optimization algorithms that can vary the sequence and parameters of processing stages according to appropriate optimality criteria will allow convenient evaluation of alternative manufacturing sequences and materials to obtain design that are optimized for quality, performance and cost. Source of material databases and process models will be identified and an extensible library of model features will be developed that allows use of new processes and materials. A survey of Phase I in order to obtain inputs regarding customer requirements; the responding organizations will be the basis for technology transfer and commercialization

Keywords:
simulation metal forming visualization process design optimal design process modeling material proce

AES proposes to continue the development of a computer platform for simulation-and-optimization-based design of multiple-stage manufacturing processes. The main objective of the Phase II effort is to develop an extensible software frame work for the integration of models for materials, processes, equipment, cost, basic design principles and methods, optimization algorithms and visualization capabilities. Analytical models of metal forming and related processes will be implemented in the design system. By connecting simulations and visualization mechanisms for each of the stages of a manufacturing process, this framework will enable the evaluation of manufacturing alternatives to improve quality, performance, producibility, and cost. A mature state-of-the-art, adaptive modeling language compatible with the latest standards for distributed computing and Internet/intranet accessibility, and its associated software environment will be utilized as the object-oriented, feature-based framework for integration. An advisory committee comprising industrial, research, and academic organizations will be formed at the beginning of Phase II with the objective of refining requirements about modeling and functionality issues during the development. The advisory committee will also serve as a first mechanism for technology transfer and commercialization. With the participation of an industrial collaborator, the value of the design system will be validated on an engine disk-manufacturing problem of importance to the Air Force

Keywords:
material process design metal forming simulation visualization optimization optimal design process