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

这个探索性研究（SGER）奖的小补助金为安全关键部件锻造中基于风险的工艺设计的探索提供资金。 这一探索将涉及：（1）开发适用于获取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）开发建模过程风险所需的分析基础，以及（3）探索适用于在存在风险的情况下优化过程设计的计算模型。 将特别强调估计和衡量特定制造工艺替代品的风险分布。 将描述净成形锻造下的点缺陷密度泛函变换，以捕捉与特定设计方案相关的风险，并将为工艺优化建立设计评估和相关净成形风险模型，如果成功，本研究的结果将导致锻造工艺设计和制造操作的改进。 预计这些工艺改进可以使净成形技术适用于制造机身结构部件、直升机旋翼毂、航空发动机叶片、涡轮机转子、汽车轮轴等，导致显著的制造成本降低和改进的性能风险概况。 这项工作也将有助于基于风险的有限元计算工具和方法的工程最佳金属成形操作。

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.