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Research Papers: Design Automation

An Inverse, Decision-Based Design Method for Integrated Design Exploration of Materials, Products, and Manufacturing Processes

[+] Author and Article Information
Anand Balu Nellippallil

Aerospace and Mechanical Engineering,
University of Oklahoma,
Norman, OK 73019
e-mail: anand.balu@ou.edu

Vignesh Rangaraj

Industrial and Systems Engineering,
University of Oklahoma,
Norman, OK 73019
e-mail: rangaraj.vignesh@ou.edu

B. P. Gautham

TCS Research,
54-B, Hadapsar Industrial Estate,
Pune 411013, Maharashtra, India
e-mail: bp.gautham@tcs.com

Amarendra Kumar Singh

Materials Science and Engineering,
Indian Institute of Technology Kanpur,
Kanpur 208016, India
e-mail: amarendra@iitk.ac.in

Janet K. Allen

School of Industrial and Systems Engineering,
202 W Boyd Street, Room 116-G,
University of Oklahoma,
Norman, OK 73019
e-mail: janet.allen@ou.edu

Farrokh Mistree

Aerospace and Mechanical Engineering,
University of Oklahoma,
Norman, OK 73019
e-mail: farrokh.mistree@ou.edu

1Corresponding author.

Contributed by the Design Automation Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received March 1, 2018; final manuscript received July 19, 2018; published online September 7, 2018. Assoc. Editor: Yan Wang.

J. Mech. Des 140(11), 111403 (Sep 07, 2018) (17 pages) Paper No: MD-18-1173; doi: 10.1115/1.4041050 History: Received March 01, 2018; Revised July 19, 2018

A material's design revolution is underway with a focus to design the material microstructure and processing paths to achieve certain performance requirements of products. A host of manufacturing processes are involved in producing a product. The processing carried out in each process influences its final properties. To couple the material processing-structure-property-performance (PSPP) spaces, models of specific manufacturing processes must be enhanced and integrated using multiscale modeling techniques (vertical integration) and then the input and output of the various manufacturing processes must be integrated to facilitate the flow of information from one process to another (horizontal integration). Together vertical and horizontal integration allows for the decision-based design exploration of the manufacturing process chain in an inverse manner to realize the end product. In this paper, we present an inverse method to achieve the integrated design exploration of materials, products, and manufacturing processes through the vertical and horizontal integration of models. The method is supported by the concept exploration framework (CEF) to systematically explore design alternatives and generate satisficing design solutions. The efficacy of the method is illustrated for a hot rod rolling (HRR) and cooling process chain problem by exploring the processing paths and microstructure in an inverse manner to produce a rod with specific mechanical properties. The proposed method and the exploration framework are generic and support the integrated decision-based design exploration of a process chain to realize an end product by tailoring material microstructures and processing paths.

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Figures

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Fig. 1

Olson's hierarchical concept of materials-by-design [3]

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Fig. 2

The vertical and horizontal integration of models with information flow for the hot rod rolling process chain

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Fig. 3

The computing infrastructure for CEF

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Fig. 4

Generic form of the goal-oriented, inverse method illustrated using steps 1 and 2

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Fig. 5

Schematic of the proposed goal-oriented, inverse method for the hot rod rolling process chain problem

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Fig. 6

Ternary plot for goal 1—yield strength

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Fig. 7

Ternary plot for goal 2—tensile strength

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Fig. 8

Ternary plot for goal 3—hardness

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Fig. 9

Ternary plot—ITT solution space

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Fig. 10

Ternary plot—ferrite fraction solution space

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Fig. 11

Superimposed ternary plot

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Fig. 12

Ternary plot—ferrite grain size

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Fig. 13

Ternary plot—ferrite fraction

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Fig. 14

Ternary plot—pearlite interlamellar spacing

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Fig. 15

Superimposed ternary plot for all goals

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