Combining Physical and Statistical Methods for Modeling Novel Manufacturing Processes

9415001 Finger该奖项是因为创建了一种方法，用于使用统计方法、物理模型和实验来获取新制造工艺的过程模型。将要研究的过程是形状沉积熔化过程，这是一种固体自由形状制造过程。该零件是通过使用微铸造工艺在薄层中连续沉积钢和铜等熔融材料而建立起来的。使用的其他子工艺有热喷涂、喷丸和机械加工。只有微铸造和加工子过程将使用所提出的方法进行研究。实验的统计设计将被用来创建粗略的过程模型，以确定重要的过程变量及其之间的关系。对于目前还不能很好理解的子过程，将根据子过程的基本物理原理开发模型。不同复杂程度和详细程度的代理模型也将从详细模型中抽象出来。即将开发的方法学对研究形状沉积过程特别有用，这是一种快速成型过程。更传统的进程也将受益于这一方法。

9415001 Finger The award is for creating a methodology for acquiring process models of novel manufacturing processes using statistical methods, physical models, and experimentation. The process that will be studied is the shape deposition melting process, which is a solid freeform fabrication process. The part is built up by successively depositing molten materials, such as steel and copper, in thin layers using a microcasting process. Other subprocesses used are thermal spraying, shot peening, and machining. Only the microcasting and machining subprocesses will be studied using the proposed methodology. Statistical design of experiments will be used to create coarse process models that identify important process variables and relationships among them. For subprocesses not well understood at present, models will be developed based on the underlying physics of the subprocesses. Surrogate models of different levels of complexity and detail will also be abstracted from the detailed models. The methodology to be developed is particularly useful for studying the shape deposition process which is a rapid prototyping process. More conventional processes would also benefit from the methodology.