Utilizing an ICME Approach For Ensuring Quality Casting in ...Materials Engineering (ICME) ICME is...

Copyright © ESI Group, 2009. All rights reserved.Copyright © ESI Group, 2009. All rights reserved.

Utilizing an ICME Approach For

Ensuring Quality Casting in

Shipbuilding

Tony Davenport, Manager Aerospace & Defense

Adi Sholapurwalla, General Manager, ESI NA

December 9, 2015

1

Copyright © ESI Group, 2009. All rights reserved.Copyright © ESI Group, 2014, All Rights ReservedMoving Manufacturing to the Left

What is “Moving Manufacturing to the Left”

Empower designer/analysts to work on parts “as built” not

“as designed”.

Early understanding of localized material changes

and potential defects that occur during the manufacturing

process to ensure part life is significantly increased.

Material Changes and Defects are carried through the

performance analysis to predict failures during

environmental usage.

Concurrent engineering among multiple business

disciplines allow design, process and manufacturing

engineers to work as a team by making materials

information more readily available earlier in the design

cycle.

Produce higher quality parts, right the first time


Reduce risk that may cause

mission failure or loss of life.

Avoid costly logistics and warranty

issues due to build defects.

Avoid costly (time and $$)

expenses caused by tooling

mistakes and rework.

Ensure that same parts work the

same.

Ultimately…Improve system and

part life expectancy to be able to

complete the mission and know

manufacturing risks earlier in the

product life cycle.

Benefits of

Moving Manufacturing to the Left

3


What’s Important about

Moving Manufacturing to the Left?

4

The largest gap in terms of expected cost and expected spend

occurs during the jump from technology to manufacturing

development.

Ultimately, this is the area where the least amount of M&S tools are

utilized, but very much needed.Courtesy: US AFRL ManTECH

Program

https://www.dodmantech.com/ManTechPrograms/Files/AirForce/Cleared_MML_for_website.pdf


Requirements Analysis

Conceptual Design

Preliminary Design

CAE/CAD/CAM Based

Design

Test & Evaluation

Production & Deployment

Operations & Sustainment

What’s Missing Today?

5

MBSE MBE MBM

Systems Engineering Design Engineering Manufacturing

User

Needs

“Function Centric” “Geometry Centric” “Operation Centric”

“Virtual Wall” “Virtual Wall”

Current State of M&S


Conceptual Design

Preliminary Design

Detail Design Optimization

Test & Evaluation


Conceptual Design

Preliminary Design

Detail Design Optimization

Test & Evaluation

Production & Deployment

Operations & SustainmentM&S M&S M&S M&S M&S

User

Needs

Producer

Needs

Transforming the Design Space

“Fit-Form-Function-Operation Centric”

MBSE MBE MBM

“Virtual World”Complex System Design & Development

Manufacturing Enterprise Design & Development

“Physical World”Engineering

M&S Based

Trade Studies

Manufacturing

“Re-Engineering” Design and ManufacturingReference NDIA presentation “21st Century Aerospace and Defense M&S

Needs and the Virtual Manufacturing Frontier by Dr. Al Sanders Presented

to NDIA SE M&S Committee, Washington, DC, June 19, 2012


Integrated Computational

Materials Engineering (ICME)

ICME is an approach to design products, the materials

that comprise them, and their associated materials

processing methods by linking materials models at

multiple length scales. The focus is on the materials, i.e.

understanding how processes produce material

structures, how those structures give rise to material

properties, and how to select materials for a given

application.

Materials, Manufacturing Methods and Component

Design (& Structural Analysis) are Strongly Coupled

6

Design

MfgMtls

http://en.wikipedia.org/wiki/Material

http://en.wikipedia.org/wiki/Microstructure

http://en.wikipedia.org/wiki/List_of_materials_properties

http://en.wikipedia.org/wiki/Material_selection


Manufacturing Materials Is

Complicated

But Very Actual Today…



As-Built & not As-Designed

PROCESS GEOMETRY MATERIALS

CASTING PROCESSSIMULATION

RESIDUAL STRESSES

DISTORTIONDEFECTS MICROSTRUCTURE

HEATTREATMENT

RESIDUAL STRESSES

DISTORTIONDEFECTS MICROSTRUCTURE

LOCAL MECHANICAL PROPERTIESCOMPONENT

GEOMETRY

Life time prediction, performance…

TH

ER

MO

DY

NA

MIC

DA

TA

BA

SE

S

DESIGN


In CastingGas and Micro Porosity

Segregation

Shrinkage and Piping

Inclusions

Hot Tears

Forming & ForgingCracks

Flakes

Residual Stresses

Embrittlement Effects

Unfilled Sections

WeldingResidual Stresses

Cracks

Gas Inclusions

CompositesPorosity

Bonding Defects

Fiber Misalignment

Delamination

Common Examples of Defects in

Manufacturing (Short List)

9

Porosity Inclusions

Cracks

Delamination

Distortion

Flakes


EXAMPLES OF MOVING

MANUFACTURING TO THE LEFT

Successful

10


No Manufacturing Influence

Failure Initiation

Example 1: Casting

Re-engineering based on Failure Location

In a Linear Static Model,

without taking into

account materials

changes…

You can chase the high

stress around the model

Thicken Here…

Thicken There…

And never actually find

the location of physical

failure.

Copyright © ESI Group, 2009. All rights reserved.Copyright © ESI Group, 2014. All rights reserved.Moving Manufacturing to the Left

No Manufacturing Influence

Failure Initiation Failure Initiation

Example 1: Casting

Re-engineering based on Failure Location

With Porosity Influence


Example 2: Welding

Effects of Welding Residual Stresses

Courtesy: EDAG

Test Set-Up for Drop Silo (Aluminum 6063 T6)


Example 2:

Residual Stresses and Distortions

Courtesy: EDAG

Model without Manufacturing Effects Model with Manufacturing Effects

HAZ: Heat Affected Zone


- Part and loads are symmetric; however, physical tests consistently show failure off-

centered, on left side of structure

- Theoretical stress analysis shows

uniform risk of failure long net structure

- “As-Built” stress analysis shows

highest risk of failure off-centered,

on left side of structure

Example 3: CompositesEffects of Draping on Mechanical Performance

Airframe Load Test:Courtesy: EADS-M

Air Frame rupture test

Failure experimentally observed

Failure Criterion

As-Built Fiber

Orientation Failure Criterion


Example 4: Composite Forming

CF Wing Rib Thermoforming

16

Courtesy: British AerospacePress & Tooling


Example 4: Composites


17

Press Formed Rib (bindered 2x2 twill CF)

Before Forming: flat sheet

Courtesy: British AerospaceAfter Forming: cured part (requires only

trimming)

Copyright © ESI Group, 2009. All rights reserved.Copyright © ESI Group, 2009. All rights reserved. 18

Results

Courtesy: British Aerospace






19

Validation against detail structures

UD CF/epoxy prepreg [+45°/-45°]s

Courtesy: British AerospaceActual Formed Part Simulated Part


MOVING MANUFACTURING TO THE LEFT

ESI NA Portfolio

20


virtual realit

y

The only CAE Solution

That Aligns with

National Research

Council’s Vision of

ICME

Integrated

Computational

Materials

Engineering

ESI VIRTUAL PRODUCT ENGINEERING


MOVING MANUFACTURING TO THE LEFT

Ongoing & Future Projects

22


Co-Funded Projects


HOW5 MAI: Modeling Advancement for Aerospace Investment Castings

PNNL: Investigation of Microstructural Evolution During Solidification and Heat-treatment in a Die-Cast Magnesium Alloy

Honeywell DARPA: Rapid Low Cost Additive Manufacturing via DMLS (Additive Manufacturing)

USCAR: Project to Validate Crash Models for Carbon Fiber Composites to Enable Production-Feasible Composites in Primary-Structural Automotive Crash and Energy Management Applications

GM: Development of Carbon Fiber Composite Reinforced Rocker and Floor Pan.

NMC: Weld Sequencing Optimization to Minimize Distortion


Simulating AM parts prior to

build, can provide engineers

with most important variables

to control during the build

process to ensure a predictable

life-expectancy of the part.

Simulating AM parts is less

expensive than printing many

parts to find that most fail prior

to their life-expectancy.

Simulating Additive Manufacturing

24


MAI-HOW5 Program Overview

Program Goal: Elevate the accuracy, speed, and utility of

casting process modeling

Increase casting yield

Reduce waste

Accelerate new casting product development

Sustain the competitive edge for the domestic production

Funded by MAI and NGCI

Include team members across the entire industry

5-year, $4.3M program including industry cost share

System Customers

Aerospace Engine

OEMs

Investment Casting

Producers

Software

Developers

and Consults


Vary Weld Sequence Until Distortion Is Minimized.

Runtimes are based on number of CPU’s & Licenses available.

NMC Project: Weld Sequence

Optimization to Minimize Distortion

Sensitivity AnalysisStochastic Analysis

Optimization

Phoenix Integration

ModelCenter

Build

Automated

Workflows1

Execute

Multiple

Runs2

Evaluate

Trade-Offs3

ESI NA Weld Planner

Minimize Weld Distortion

Through Sequence Optimization


Huntsville, AL Santa Clara, CASan Diego, CAColumbia, MD St. Louis,

MO

ESI North America

Farmington Hills,

MI

Global Foot print with 30

offices world-wide

6 offices in 5 states

North America Headquarters in Farmington Hills, MI

150+ peopleR&D

Engineering Services

Onsite contractors

Sales and marketing


Global Customer References

28

http://www.istockphoto.com/stock-illustration-6597215-car.php?st=febf9af

http://www.istockphoto.com/stock-illustration-6597215-car.php?st=febf9af

http://www.istockphoto.com/stock-illustration-12509068-cog-stack.php?st=422b0cd

http://www.istockphoto.com/stock-illustration-12509068-cog-stack.php?st=422b0cd

http://www.istockphoto.com/stock-illustration-19634315-high-voltage-wire.php?st=c5558fe

http://www.istockphoto.com/stock-illustration-19634315-high-voltage-wire.php?st=c5558fe

http://www.istockphoto.com/stock-illustration-10660150-army-tank.php?st=48a78b0

http://www.istockphoto.com/stock-illustration-10660150-army-tank.php?st=48a78b0

http://www.istockphoto.com/stock-illustration-6595442-boeing-747.php?st=29009b8

http://www.istockphoto.com/stock-illustration-6595442-boeing-747.php?st=29009b8

http://www.istockphoto.com/stock-illustration-19450562-electronics-icons.php?st=d482c23

http://www.istockphoto.com/stock-illustration-19450562-electronics-icons.php?st=d482c23

http://www.istockphoto.com/stock-illustration-15984489-hurryup.php?st=c5771c9

http://www.istockphoto.com/stock-illustration-15984489-hurryup.php?st=c5771c9


Academic Partners200 +

29

Massachusetts Institute of Technology

http://web.mit.edu/aboutmit/


Utilizing an ICME Approach For

Ensuring Quality Casting in

Shipbuilding

Tony Davenport, Manager Aerospace & Defense

Adi Sholapurwalla, General Manager, ESI NA

December 9, 2015

30

Utilizing an ICME Approach For Ensuring Quality Casting in ...Materials Engineering (ICME) ICME is...

Documents

Transcript of Utilizing an ICME Approach For Ensuring Quality Casting in ...Materials Engineering (ICME) ICME is...