SGER/Collaborative Research: Investigating Probability Laws in the Design of Manufacturing Processes for Safety Critical Parts

这一小额探索性研究(SGER)奖为探索基于风险的工艺设计提供资金，用于锻造安全关键部件。这一探索将涉及：(1)开发适合于捕捉变形加工中点缺陷位置和严重程度的概率规律的蒙特卡罗方法，(2)开发对工艺风险进行建模所需的分析基础，以及(3)探索适合于在存在风险的情况下优化工艺设计的计算模型。将特别强调估计和衡量特定制造工艺备选方案的风险分布。净形锻造下的点缺陷密度泛函变换的特征是捕捉与特定设计方案相关的风险，设计评估和相关的净成形风险将被建模用于工艺优化。如果成功，本研究的结果将导致特别是锻造工艺的设计和总体制造操作的改进。预计这些工艺改进将使净成形技术适用于机身结构部件、直升机转子轮毂、航空发动机叶片、涡轮转子、汽车车轴等的制造，从而大幅降低制造成本并改善性能风险状况。这项工作还将有助于基于风险的有限元计算工具和方法，以设计最佳的金属成形操作。

This Small Grant for Exploratory Research (SGER) award provides funding for an exploration of risk-based process design in the forging of safety critical parts. This exploration will address: (1) development of Monte Carlo approaches suitable for capturing the probability law on the location and severity of point defects in deformation processing, (2) development analytical foundations necessary to model process risk, and (3) exploration of computational models suitable for optimizing process design in the presence of risk. Particular emphasis will be given to estimating and measuring the risk distribution for specific manufacturing process alternatives. Point-defect density functional transformations under net shape forging will be characterized to capture risk associated with specific design alternative, and the design valuations and the associated net shaping risk will be modeled for process optimization.If successful, the results of this research will lead to improvements in the design of forging processes in particular and manufacturing operations in general. It is anticipated that these process improvements could make net shaping technology suitable for the manufacture of airframe structural parts, helicopter rotor hubs, aeroengine blades, turbine rotors, automotive axles etc., leading to dramatic manufacturing cost reductions and improved performance risk profiles. This work will also contribute to risk based finite element computational tools and methodologies for the engineering of optimal metal forming operations.