Exploratory Research on Engineering the Transport Industries (ETI): Robust Planning for Routing

这项运输工业工程探索性研究（ETI）拨款为开发一种数字工具提供资金，用于确定批量成形过程中的最佳工艺参数，如轧制、挤压和锻造。开发的数值工具将确定最佳的工艺几何形状；在给定的二维成形过程中，满足特定设计标准的温度和速度。基于自适应任意拉格朗日-欧拉有限元公式的优化算法将用于模拟大变形热弹粘塑性接触问题。该算法将在现有的高级计算框架中实现，该框架具有网格生成、自适应和并行计算工具。还将进行涉及挤压过程的实验，以验证所开发的算法。实验模具将根据本工作预测的最佳模具形状制造，并在预测的最佳模具速度下进行测试。在实验中，我们将使用一台可以挤出带有网格标记的橡皮泥材料的模型压力机来观察材料的流动行为。如果成功，这项研究的结果将导致改进的整体成形工艺设计和处理复杂非线性问题的优化方法的新发展。这项工作的主要目标是确定最优的工艺几何形状，热条件和工艺速度，在散装成形过程中，将满足通常规定的设计标准。这些设计标准可能包括产生均匀的材料流动，在成形产品中产生特定的材料特性分布，最大限度地减少生产时间，或最大限度地减少工艺所需的能量。确定实现这些目标的工艺参数将有助于在挤压和锻造等过程中降低成本并提高最终产品的质量。所提出的工作也将有助于计算工具和方法可用于非线性优化问题。

This Exploratory Research on Engineering the Transport Industries (ETI) grant provides funding for the development of a numerical tool for determining optimal process parameters in bulk forming processes, such as rolling, extrusion, and forging. The developed numerical tool will determine the optimal process geometry; temperature and speed that satisfy specified design criteria for a given two-dimensional forming process. An optimization algorithm based on an adaptive arbitrary Lagrangian-Eulerian finite element formulation for modeling large deformation thermo-elasto-viscoplastic contact problems will be used. The algorithm will be implemented in the context of an existing advanced computational framework that has tools for mesh generation, adaptively, and parallel computing. Experiments involving the extrusion process will also be performed to validate the algorithms developed. Experimental dies will be manufactured according to the optimal die shapes predicted in this work and tested at the predicted optimal die speeds. A model press, which can extrude plasticine material marked with a grid, will be used in these experiments to observe the material flow behavior.If successful, the results of this research will lead to improvements in the design of bulk forming processes and new developments in optimization methods for handling complex non-linear problems. The primary goal of this work is to determine optimal process geometry, thermal conditions, and process speed in bulk forming processes that will satisfy typically prescribed design criteria. These design criteria may include generating a uniform flow of the material, generating a specified material property distribution in the formed product, minimizing the production time, or minimizing the energy required for the process. Determining the process parameters to achieve these objectives will help to reduce the cost and improve the quality of the final product in processes such as extrusion and forging. The proposed work will also contribute to the computational tools and methodologies available for nonlinear optimization problems.