https://popups.uliege.be/esaform21/index.php?id=4352 fr Fri, 02 Apr 2021 12:35:47 +0200 Thu, 08 Apr 2021 08:54:54 +0200 https://popups.uliege.be/esaform21/index.php?id=4352 0 https://popups.uliege.be/esaform21/index.php?id=4425 Manufacturing translates ideas, innovation and raw materials into products used by societies as a driving force for raising their living standards. To enhance the versatility of manufacturing processes and to fully integrate design and manufacturing for system optimization, research efforts at Cao’s group are rooted in advancing new flexible manufacturing processes, and in enhancing system optimization using the combination of the ICME (integrated computational materials engineering) and data-driven approaches. This talk will provide a quick overview of these activities and then focus on selected processes, i.e., rapid dieless forming for producing three-dimensional sheet parts without geometry-specific tooling, and metal-based powder-blown additive manufacturing. The integration of the fundamental process mechanics, techniques including machine learning to achieve effective and efficient predictions of material behavior compared to conventional methods, and process control paves the foundation for translating expertise and skills from the hands of a few to hands of many. Fri, 02 Apr 2021 15:55:01 +0200 https://popups.uliege.be/esaform21/index.php?id=4425 https://popups.uliege.be/esaform21/index.php?id=4633 In the field of AM, and specifically metal Powder bed fusion, which is the subject of this presentation, a lot of progress has been made. Today, for example, AM allows us to have affordable low volume production, and new design methods allow for optimal designs that were not manufacturable before. But in order to make the next step and go to zero inventory or individualization of products, it is the view of Siemens that a more integrated and automated software process chain is needed. In general, todays’ software chain, is too fragmented and does not allow updates in the design to move quickly through the entire production chain.  In this presentation we will show our End-to-end platform applied to a combustion chamber from a Siemens Energy gas turbine.  In this example we move from virtual product to virtual production to production planning to physical production, while the entire chain is integrated and managed in one unique environment. One of the main functionalities needed for AM is the ability to design for AM, which means CAD functionalities, topology optimization and the ability to integrate lattice structures. The designed part is then connected to production preparation and process simulation in an associative way, i.e. an update made to the design, at a later stage, will propagate through the chain automatically. One special point of focus is the possibility to remove support structures in an automated way, in order to fully automate the chain and to be able to scale up production to cost and quality. In the second part of the presentation we focus on process simulation, because in order to reach first time right printing, we need to predict problems like re-coater collision and part distortion. If these problems cannot be predicted accurately, they will have to be solved on the printer by printing the parts, and thus impeding industrialization of quick design updates. For the distortion analysis we use an enhanced inherent strain method using a full thermo-mechanical analysis. We initially focus on the thermal analysis, in order to tackle local overheating. Local overheating is closely linked to re-coater collision, together with global distortion. The quality of the global distortion is also important of itself, because it allows us to pre-distort the part before printing and obtain a geometry close to nominal geometry after printing. Wed, 07 Apr 2021 14:59:04 +0200 https://popups.uliege.be/esaform21/index.php?id=4633 https://popups.uliege.be/esaform21/index.php?id=4634 Materials with significantly different thermomechanical properties and processability are frequently used both as alternatives and as competitors for demanding LW applications. These materials reveal different microstructures and a very wide range of structure-property-performance relationships. The structure originates from the specific processing, hence, it is of prime practical and theoretical importance to predict these microstructure features and relationships for prognosticating the service behavior of the specific components. In the first part of the lecture a brief overview will be given about solid state forming of continuous fiber reinforced composites with thermoset (CFRP) and thermoplastic matrix (organosheets and TPC) and about the processing of discontinuous fiber reinforced composites (injection molded SFRP and compression molded CF-SMC). The overview involves the typical processing and simulation methods along with the material parameters necessary for these materials. To demonstrate these methods, use cases for draping simulation of CFRP and for thermoforming simulations of organosheets (2D fabrics) and for TPC (UD tapes) will be briefly introduced. A more detailed description of the methodology for designing and producing discontinuous fiber reinforced compression molded CF-SMC components on different complexity scales with particular focus on the determination of proper parameters for process and component performance simulations is provided in the second part of the lecture. Finally, a perspective to improve above engineering methodologies towards a fully integrated Life Cycle Analysis (LCA) of these materials within the integrated simulation methodology is introduced. Wed, 07 Apr 2021 15:01:32 +0200 https://popups.uliege.be/esaform21/index.php?id=4634 https://popups.uliege.be/esaform21/index.php?id=4636 The aim of regenerative medicine is to repair a tissue or organ of our body that cannot heal by itself. Typically, this is done by the use of cells, porous materials, and biological factors used either alone or in combination. When porous materials are used, such cellular solids act as a scaffold for cells to be housed and placed in the conditions to thrive to make those proteins that form our tissues. This interplay between cells and scaffolds requires an exquisite control of the design, fabrication, and eventual post-modification of scaffolds (1, 2). In this presentation, I will show through a few examples how processing technologies taking inspiration from the material-forming field can be used to design and fabricate scaffolds with instructive properties. Such scaffolds are able to communicate with cells and persuade them to perform programmed activities towards the regeneration of targeted tissues. Wed, 07 Apr 2021 15:04:08 +0200 https://popups.uliege.be/esaform21/index.php?id=4636 https://popups.uliege.be/esaform21/index.php?id=4780 Although major technical project orientations are usually well considered in projects from the early stage of the design process (examples: solution made of steel or concrete, steel grade A or B?, welded joins or bolted connections,…) other details – “small details” in appearance – are usually only considered during last stages of the design process (examples: laser cutting or punching, crane A or crane B, M30 bolts or M36 bolts …). Designers will often consider that “small details” are for “design optimization” and not for “design orientation”. Although this consideration is correct in many cases, some applications are much more sensitive to these “small details”. If wrongly anticipated, they can lead to significant costs and difficulties during on-site assembly and erection processes or to safety and transportation issues. The consideration of these parameters in calculations is not always straight forward and, in many cases, is based on experience. Some parameters may be transparent during the structural calculations while they will create big questions on feasibility and cost when site operations will be addressed. Other parameters will show great potential on paper while they may generate major difficulties during site operations. “if not properly designed: what works well on paper may be significantly more difficult on site” In the presentation, we will go through examples (taken from the actual experience of the CRM Group) to illustrate how feasibility and cost of the solution can be significantly influenced by Manufacturing, Transportation and Assembly parameters. The key message of the presentation is : “The sooner Manufacturing, Transportation and Assembly parameters are included into the design process, the better it is”. Fri, 09 Apr 2021 09:47:13 +0200 https://popups.uliege.be/esaform21/index.php?id=4780