Multi-Scale Modeling Tools to Enable Manufacturing-Informed Design

Improving Product and Manufacturing Process Design through a More Accurate Modeling Framework

Introduction This project aims to fill the knowledge gap between upstream design and downstream manufacturing processes by developing a manufacturing-informed design framework enabled by multiscale New multi-scale modeling tools will enable more accurate modeling of machining physics-based process models. This processes, which will result in improved productivity. Graphic credit Third Wave Systems. framework will enable product and process designers to: fluid. This inefficient trial-and-error process produces significant waste streams at the • Evaluate the effects of design changes unit cell and plant level and incurs unnecessary financial and energy losses. and material selection on component performance, cost, and quality. Available at every stage of a product’s lifecycle, the computational tools developed through this effort will help manufacturers accurately model machining processes, • Anticipate manufacturing quality enabling improved productivity. and cost issues ahead of shop floor implementation. Benefits for Our Industry and Our Nation • Select and tailor manufacturing The modeling advancements envisioned could potentially provide a 50% improvement processes to achieve low-waste, low- in machining process productivity. This productivity increase would be achieved cost processes without compromising through the reduction of machining cycle times, waste streams, energy consumption, quality. and carbon emissions while improving the energy efficiency of new product designs. Design engineers would use the modeling framework to develop lightweight, efficient During process or product design, products with optimal designs; and manufacturing engineers would be able to design U.S. manufacturers understand the optimal manufacturing processes that require less energy and raw materials while characteristics and capabilities of assuring quality, performance, and costs. Ultimately, the computational framework and manufacturing processes but do not related tools will promote sustainable manufacturing practices while preserving the account for the dynamic responses and economic and innovative edge of U.S. manufacturing. The new tools have the potential variability of tooling, materials, and to save more than $1 billion in annual tooling costs and $24 billion in cutting fluid costs, equipment. The design community lacks and total energy savings are estimated at 4.1 trillion BTUs per year. accurate, easy-to-use, detailed physics- based process modeling tools to inform Applications in Our Nation’s Industry and guide the design process through a better understanding of machining While the design framework will initially focus on metal machining, its generic processes. Consequently, products and implementation will be applicable to a broad range of manufacturing processes. The machining processes are often over- or expected fundamental advances in material and manufacturing science will present under-designed, and design teams must opportunities to improve casting, forging, stamping, extrusion, assembly, and additive perform many process trials that are manufacturing processes. The U.S. manufacturing supply base will benefit from based on conservative estimates coupled improvements in productivity, quality, cost, and environmental impact—benefits most with slow cycle times, frequent tool immediately realized by the aerospace, automotive, power generation, medical device, replacements, and liberal use of cutting precision machining, and mining and heavy equipment manufacturing sectors.

ADVANCED MANUFACTURING OFFICE ADVANCED MANUFACTURING OFFICE

Project Description Milestones Project Partners The project objective is to develop and This project began in 2012. Third Wave Systems, Inc. demonstrate a new manufacturing- Minneapolis, MN informed design framework that will • Demonstrate ability to predict trends Principal Investigator: Troy Marusich utilize advanced multi-scale physics- in material characteristics in machined E-mail: [email protected] based process modeling to dramatically parts based on qualitative agreement of improve manufacturing productivity trends for extreme machining condi- Georgia Institute of Technology and quality while reducing the costs of tions (2013). Atlanta, GA machined components. A combination • Establish capability to predict grain Pennsylvania State University of advanced microstructural prediction size and dislocation density based on University Park, PA models and physics-based modeling first principles, as well as statistical tools will enable the framework to more models that incorporate variability into Purdue University West accurately predict machined component predictions of surface roughness and Lafayette, IN quality and engineering performance. residual stresses (2014). University of California, Santa Barbara Barriers • Demonstrate capability for advanced Santa Barbara, CA • Integration of multi-scale models. process optimization using algorithms that include control of workpiece For additional information, • Computational modeling at the micro- surface characteristics (2015). please contact and multi-scale level. • Demonstrate integrated framework for Bob Gemmer • High computational speed requirements predicting and designing workpiece Technology Manager surface characteristics and component U.S. Department of Energy • Accuracy of the new physics-based performance (2015). Advanced Manufacturing Office process modeling components. Phone: (202) 586-5885 Email: [email protected]  Commercialization Pathways During the project, input from The design framework will be produced manufacturing stakeholders using an integrated approach that will be incorporated to enhance unites relevant aspects of material commercialization. Third Wave Systems, science, manufacturing science, and Inc. intends to embed computational statistical theory. Metal machining will process modeling and optimization be used to demonstrate the framework tools developed within its commercially and associated benefits. This project available software to enable immediate will deliver the following technical adoption by U.S. manufacturers. Beta advancements: launch customers will be closely involved in commercialization activities and will • Development of advanced, first-prin- provide testing, technical guidance, ciples-based microstructural modeling and feedback during the entire project. tools for metals that encounter severe The modeling architecture uses process plastic deformation. modeling software, which will enable • Enhancement of machining process rapid insertion into manufacturers’ models by incorporating university computer-aided design/computer-aided partner research results. manufacturing environments.

• Development of a multi-scale modeling framework.

For more information, visit: manufacturing.energy.gov

DOE/EE-0879 • Updated February 2015