SBIR-STTR Award

To meet DoD future weapons systems, such as JSF, requirements for major cost reductions without sacrificing quality or reliability will require the development and implementation of new design tools. While simulation and computerization has been aggressively applied in many areas of the manufacturing enterprise, one critical area which has been largely ignored is metalworking process simulation. The few simulation tools available today are based upon Finite Element Analysis models which are slow and are more useful for verification and validation of design parameters than as process development tools. Systems approaches must be developed which will embed analytical models of basic transport phenomena into appropriately simplified design models to allow product engineers the ability to rapidly simulate multiple design and process routes and parameters for multi-stage manufacturing processes. Feature based interoperable design systems which will facilitate the implementation of collaborative process development with the supplier base are needed. The objective of Phase I is to investigate the feasibility of providing the needed tools for rapid interactive integrated product/process development through currently available simulation software modules, frameworks, and development efforts, especially within government agencies and programs. A method for making this system commercially available and viable is also proposed

To meet DoD future weapons systems requirements, such as the JSF, for affordability without sacrificing quality or reliability will require the development and implementation of new design tools. While simulation and computerization has been aggressively applied in many areas of the manufacturing enterprise, one critical area which has been largely ignored is metalworking process simulation. The few simulation tools available today are based upon Finite Element Analysis models which are slow and are more useful for verification and validation of design parameters than as process development tools. Systems approaches must be developed which will embed analytical models of basic transport phenomena into appropriately simplified design models to allow product engineers the ability to rapidly simulate multiple design and process routes and parameters for multi-stage manufacturing processes. Feature based interoperable design systems which will facilitate the implementation of collaborative process development with the supplier base are needed. The objective of Phase II is to develop axisymmetric forging models and 3D die design tools that will be useful and desirable to industry and will demonstrate the value of the simulation-based design system. A further objective is to develop inherent in-house capabilities to be able to readily extend the system to incorporate models of other processes such as ring rolling and cogging. A method for making this system commercially viable is also proposed