Development of a Robust Computational Design Simulator for Industrial Deformation Processes

该研究项目的目标是开发和应用数学和计算严格的基于梯度的优化方法，用于基于量化产品质量的虚拟材料工艺设计，并考虑工艺目标和约束，包括经济方面。提出了多道次金属成形过程的预成形和工艺参数优化框架。每一个单独的过程的设计是使用梯度优化技术，是基于一个创新的连续灵敏度分析。最佳的微观结构演化路径、理想的成形技术和基于知识的专家系统用于选择所需的工艺顺序和开发可行的初始设计。如果成功，正在开发的计算设计模拟器可以用于选择必要的成形和中间热阶段工艺顺序，选择合适的模具和预成型件，以及控制/设计各种工艺参数，对于具有给定初始几何形状的给定原材料，可以在各种工艺约束下以最小的利用率和总成本获得具有所需微观结构和形状的最终产品。这些发展将导致一个虚拟的过程实验室，这将有助于减少过程和产品开发的前置时间，在削减广泛的实验试错过程开发工作的成本，在开发定制材料性能的过程中，并在增加体积/时间产量。

The objective of the research project is the development and application of mathematically and computationally rigorous gradient-based optimization methodologies for a virtual materials process design that is based on quantified product quality and accounts for process targets and constraints including economic aspects. A framework for preform as well as process parameter optimization of multi-stage metal forming processes is considered. The design of each individual process is performed using gradient-optimization techniques that are based on an innovative continuum sensitivity analysis. Optimal microstructure evolution paths, ideal forming techniques and knowledge based expert systems are used to select the required sequence of processes and to develop feasible initial designs.If successful, the computational design simulator under development can be applied to select the necessary sequence of forming and intermediate thermal-stage processes, select appropriate dies and preforms and control/design the various process parameters such that, for a given raw material with a given initial geometry, one can obtain a final product with desired microstructure and shape under various processconstraints and with minimal utilization rates and overall cost. These developments will lead to a virtual process laboratory that will assist industry in reducing lead time for process and product development, in trimming the cost of an extensive experimental trial-and-error process development effort, in developing processes for tailored material properties and in increasing volume/time yield.