Process Modelling

Process modelling (finite element method, analytical models, probabilistic models) can be used to provide more comprehensive analysis or complementary approach of the process performance.

Process modelling

Predictive models can be used in a variety of ways:

  • Making better informed decisions of the manufacturing processes in a computer environment.
  • Reducing the need for costly shop floor trials to identify the root cause of defects which occur in production,
  • Shortening lead times in bringing a new product to market.

Process modelling is one of the key research areas at the AMRC.


Research

The Process Modelling Group at the AMRC is focused on the development of techniques and research of computer based models to predict manufacturing processes, including heat treatment, residual stresses, machining (metals & composites), CFD & work-holding modelling. The group has the capability to integrate process models and in-process monitoring to investigate and validate the models to develop optimised machining. The group has developed its capability for measuring near & bulk residual stresses using different techniques for model validations.

The Process Modelling Group has successfully applied process models:

  • Predict residual stress & machining distortion for tool path optimisation based on part distortions. This research includes in-process monitoring of residual stresses & distortions for process validation. The group has developed its capability for measuring near & bulk residual stresses using different techniques for model validations.
  • Chip formation analysis in metal cutting & composite machining modelling with the aim of providing a better understanding of the relationship between the many process parameters and the machining responses as trend of cutting forces, surface integrity, tool wear mechanisms, temperature distribution, chip morphology etc. The Process Modelling Group is also working closely with the Structural Testing Centre at the AMRC to characterise the material properties of super alloys at high strain rate and high temperature for process simulations.
  • For work-holding modelling analysis & fixture design. Numerical models are utilised to investigate dynamic and static performances of a variety of aerospace components. Dynamics analysis is applied to evaluate optimum fixture constraints that relates to the fixture designs, and the statics modelling is employed to investigate root causes of part geometrical and dimensional variability, which is strongly governed by external loads (machining loads and clamping loads), fixture stiffness, and contact interaction between work piece and fixture elements.
  • CFD

Capabilities

Software:

  • Abaqus, Absys, Deform, Thirdwave, Fluent
  • Matlab, C++, Fortran
  • Isight, Umetrics

Hardware:

  • Access to Supercomputer (Iceberg_ Sheffield University)

People

Technical Lead: Dr. Sabino Ayvar-Soberanis

Team members: Ignacio Blanco, Ravi Bilkhu, Krunal Rana, Dr. Vaibhav Phadnis, Dr. Shaoming Yao.