Multiphysics Modeling and Numerical Simulation in Computer-Aided Manufacturing Processes

Trzepieciński, Tomasz; Dell’Isola, Francesco; Lemu, Hirpa G.

doi:10.3390/met11010175

Cited by 10 publications

(7 citation statements)

References 162 publications

(169 reference statements)

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“…If Equation ( 9) is satisfied, the pre-steps will not affect the process, and the calculation can be performed according to Equations ( 6)- (8). If Equation ( 9) is not satisfied, this means that the pre-steps have a great influence on the production of the process.…”

Section: Calculation Of Energy Consumption and Timementioning

confidence: 99%

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Production Scheduling Optimization during Thermoforming of Ring Forgings Based on Genetic Algorithms

Chen

Xie

et al. 2022

Metals

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In the aerospace industry, many important components are made of ring forgings with characteristics of multi-variety and multi-batch. Such components have many steps and complex parameters in the thermoforming process. The process orders are dynamic and time-varying, and, thus, optimizing the total production time and energy consumption is difficult. To solve the mentioned troublesome and time-consuming problem, this work transformed the workpiece’s required heating temperature and time index into the furnace temperature change and holding time index. Based on a genetic algorithm, an integrated production scheduling optimization of ring forging heating and model forming was established. The genetic algorithm for model improvement was optimized. The optimization objective was changed by using different fitness calculation methods. A multi-time simulation algorithm was designed to calculate each heating furnace’s time and furnace temperature. The proposed optimization method was used for a thermoforming process of ring forgings. When the optimization objective was designed to consider energy consumption and time consumption comprehensively, the average time saving was 6.93%, and the average energy saving was 12.99%. When the optimization objective was designed to prioritize energy consumption, the average time saving was 3.89%, and the average energy saving was 16.53%. When the optimization objective was designed to prioritize time consumption, the average time saving was 10.35%, and the average energy saving was 10.63%. Using the scheduling results for production, compared with the practical factory data, the errors in the simulation time and energy consumption were 2.4% and 1.6%. The results show that the scheduling efficiency of integrated thermoforming production is significantly improved by using this optimization model, and the simulation results have high reliability. The energy consumption of orders is greatly reduced, and the total production time is greatly shortened.

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Section: Calculation Of Energy Consumption and Timementioning

confidence: 99%

“…Therefore, scheduling order workpieces is extremely important in this field. With the progress of industry, the manufacturing process will be more intelligent, and the production process of ring forgings will be more efficient [8,9].…”

Section: Introductionmentioning

confidence: 99%

Production Scheduling Optimization during Thermoforming of Ring Forgings Based on Genetic Algorithms

Chen

Xie

et al. 2022

Metals

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“…The above shows that in the field of aerospace, building a manufacturing system with an intelligent management control platform as the core not only has a wide range of driving effects and demonstration significance but also contributes to the standardization and high-end, which has been applied to aerospace structural parts and engines [11]. Meanwhile, it can be seen that the continuous updating of industrial concepts and the demand for high-quality equipment in the aerospace industry has promoted the development of manufacturing technology towards intelligent manufacturing and ecological production, which is significant for helping intelligent management control and integration systems further improve productivity and flexibility [12].…”

Section: Introductionmentioning

confidence: 99%

“…Meanwhile, it can be seen that the continuous updating of industrial concepts and the demand for high-quality equipment in the aerospace industry has promoted the development of manufacturing technology towards intelligent manufacturing and ecological production, which is significant for helping intelligent management control and integration systems further improve productivity and flexibility [12]. As an essential basic part, ring forgings have been widely used in the industrial field, especially in aerospace.…”

Section: Introductionmentioning

confidence: 99%

Management Control and Integration Technology of Intelligent Production Line for Multi-Variety and Complex Aerospace Ring Forgings: A Review

Huang

Cui

et al. 2022

Metals

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Large and complex ring forgings are key structural parts of the aerospace field, and their quality is closely related to the reliability of aerospace vehicles. However, high-quality production of aerospace ring forgings faces many problems, such as the long process design cycle and impoverished consistency, the difficulties of real-time detection under the severe time-varying state of the deformation process, the complexity of high-quality non-destructive testing under multitudinous defects, and the cumbersome management control of the multi-source and multi-dimensional heterogeneous data. Considering the current situation of multi-variety and multi-batch production for aerospace ring forgings, establishing an intelligent production line is a crucial means to solving the above problems and realizing the standardization and premiumization of key aerospace components. Therefore, management control and integration technology of the intelligent production line play a crucial role. An analysis, including the research progress of the intelligent computer-aided process planning (CAPP) system, the real-time detection and control system, the product quality testing system, and the intelligent management control and integration system, is systematically reviewed in this work. Through intelligently managing and controlling the integrated systems of the production line, the production efficiency of ring forgings can be effectively improved, and the production energy consumption can be remarkably reduced, which is of great significance for enhancing the manufacturing technology level of aerospace products.

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“…Производство каждого изделия, конструкции или детали является результатом длинной цепочки разнообразных действий, начиная от проектирования и заканчивая сборкой. С каждым годом в реализации этого процесса все больше места отводится различным автоматизированным программам, позволяющим не только проектировать изделия с учетом обеспечения прочности, но и полностью разрабатывать технологии их изготовления [1][2][3]. Тем не менее случаи выхода из строя изделий или даже возникновения аварийных ситуаций происходят достаточно часто [4][5][6].…”

Section: Introductionunclassified

Metallographic examination as the feedback between product quality and manufacturing

Merson,

Karavanova,

Klimanov

2022

FMT

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Despite the increasing automation of the process of designing and manufacturing metal products, their failure remains a common phenomenon. The metallographic examination is appointed, which can only be carried out at a proper level by the specialized accredited organizations to identify the causes of such incidents. A metallographic examination is a tool that acts as feedback between the output quality of products and the entire chain of numerous operations during production. The purpose of this work is, using a practical example, to demonstrate the possibility and special significance of the conclusions of the metallographic examination for the development of the product manufacturing technology. Using the high-speed plasma spraying method, the authors applied the NiCrBSi coating to the surface of the locomotive wheel pair axle to increase its wear resistance. The life bench tests of the axle revealed the main fatigue crack, the tests were stopped, and the axle was artificially broken completely. The analysis of metal quality, including chemical composition, mechanical properties (strength, ductility, and impact hardness), microstructure, metal purity according to the non-metallic inclusions, and parameters of a surface layer hardened by rolling, showed its full compliance with the regulatory documentation. The thickness and hardness parameters of the NiCrBSi coating also corresponded to the declared ones. According to the fractographic analysis, the fatigue fracture was initiated at multiple points, which was a characteristic sign of a common objective reason for the insufficient strength of a product not associated with some random factor. The metallographic examination identified that the main reason for the failure of a wheelset axle is the coating's insufficient fatigue strength. The numerous fatigue microcracks that originated in the coating grew into the base metal and led to the fatigue macrocracks formation at different height levels. The merging of these cracks led to widespread fatigue fracture surface formation.

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Multiphysics Modeling and Numerical Simulation in Computer-Aided Manufacturing Processes

Cited by 10 publications

References 162 publications

Production Scheduling Optimization during Thermoforming of Ring Forgings Based on Genetic Algorithms

Production Scheduling Optimization during Thermoforming of Ring Forgings Based on Genetic Algorithms

Management Control and Integration Technology of Intelligent Production Line for Multi-Variety and Complex Aerospace Ring Forgings: A Review

Metallographic examination as the feedback between product quality and manufacturing

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