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

2018 ◽  
Vol 140 (11) ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Vignesh Rangaraj ◽  
B. P. Gautham ◽  
Amarendra Kumar Singh ◽  
Janet K. Allen ◽  
...  
Keyword(s):  
Design Method ◽  
Integrated Design ◽  
Manufacturing Processes ◽  
Process Chain ◽  
Structure Property ◽  
Horizontal Integration ◽  
Design Exploration ◽  
Rod Rolling ◽  
Manufacturing Process Chain ◽  
Decision Based Design

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.

A Goal-Oriented, Inverse Decision-Based Design Method to Achieve the Vertical and Horizontal Integration of Models in a Hot Rod Rolling Process Chain

2017 ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Vignesh Rangaraj ◽  
B. P. Gautham ◽  
Amarendra Kumar Singh ◽  
Janet K. Allen ◽  
...  
Keyword(s):  
Manufacturing Process ◽  
Design Method ◽  
Manufacturing Processes ◽  
Process Chain ◽  
Structure Property ◽  
Horizontal Integration ◽  
Design Exploration ◽  
Unit Operations ◽  
Manufacturing Process Chain ◽  
Decision Based Design

Reducing the manufacturing and marketing time of products by means of integrated simulation-based design and development of the material, product, and the associated manufacturing processes is the need of the hour for industry. This requires the design of materials to targeted performance goals through bottom-up and top-down modeling and simulation practices that enables handshakes between modelers and designers along the entire product realization process. Manufacturing a product involves a host of unit operations and the final properties of the manufactured product depends on the processing steps carried out at each of these unit operations. In order to effectively couple the material processing-structure-property-performance spaces, there needs to be an interplay of the systems-based design of materials with enhancement of models of various unit operations through multiscale modeling methodologies and integration of these models at different length scales (vertical integration). This ensures the flow of information from one unit operation to another thereby establishing the integration of manufacturing processes (horizontal integration). Together these types of integration will support the decision-based design of the manufacturing process chain so as to realize the end product. In this paper, we present a goal-oriented, inverse decision-based design method to achieve the vertical and horizontal integration of models for the hot rolling and cooling stages of the steel manufacturing process chain for the production of a rod with defined properties. The primary mathematical construct used for the method presented is the compromise Decision Support Problem (cDSP) supported by the proposed Concept Exploration Framework (CEF) to generate satisficing solutions under uncertainty. The efficacy of the method is illustrated by exploring the design space for the microstructure after cooling that satisfies the requirements identified by the end mechanical properties of the product. The design decisions made are then communicated in an inverse manner to carry out the design exploration of the cooling stage to identify the design set points for cooling that satisfies the new target microstructure requirements identified. Specific requirements such as managing the banded microstructure to minimize distortion in forged gear blanks are considered in the problem. The proposed method is generic and we plan to extend the work by carrying out the integrated decision-based design exploration of rolling and reheating stages that precede to realize the end product.

Inverse Thermo-Mechanical Processing (ITMP) Design of a Steel Rod During Hot Rolling Process

2019 ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Pranav Mohan ◽  
Janet K. Allen ◽  
Farrokh Mistree
Keyword(s):  
Hot Rolling ◽  
Design Method ◽  
Integrated Design ◽  
Computational Design ◽  
Rolling Process ◽  
Manufacturing Processes ◽  
Mechanical Processing ◽  
Design Exploration ◽  
And Performance ◽  
Decision Based Design

Abstract The production of steel products involves a series of manufacturing processes. The material Thermo-Mechanical Processing (TMP) history at each process affects the final properties and performances of the product. Experiments and plant trials to predict these properties and performance of steel products are expensive and time consuming. This has resulted in the need for computational design methods and tools that support a human designer in realizing such complex systems involving the material, product and manufacturing processes from a simulation-based design perspective. In this paper, we present a Goal-oriented Inverse Design method to achieve the integrated design exploration of materials, products and manufacturing processes. The key functionality offered is the capability to carry out a microstructure-mediated design satisficing specific processing requirements and performance goals of the product. Given models to establish the information flow chain, a designer can use the method for the decision-based design exploration of material microstructure and processing paths to realize products in a manufacturing process chain. The efficacy of the method is tested using an industry-inspired hot rolling problem to inversely design the thermo-mechanical processing of a steel rod. The focus here is the method and associated design constructs which are generic and support the formulation and decision-based design of similar problems involving materials, products and associated manufacturing processes.

Robust Concept Exploration of Materials, Products and Associated Manufacturing Processes

2018 ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Pranav Mohan ◽  
Janet K. Allen ◽  
Farrokh Mistree
Keyword(s):  
Robust Design ◽  
Design Method ◽  
Integrated Design ◽  
Manufacturing Processes ◽  
Type I ◽  
Process Chain ◽  
Process Chains ◽  
Concept Exploration ◽  
Decision Based Design ◽  
Noise Factors

In this paper, we present robust concept exploration using a goal-oriented, inverse decision-based design method to carry out the integrated design of material, product and associated manufacturing processes by managing the uncertainty involved. The uncertainty in complex material and product systems is derived from many sources and we classify robust design based on these sources — uncertainty in noise factors (Type I robust design); uncertainty in design variables or control factors (Type II robust design); uncertainty in function relationship between control/noise and response (Type III robust design); and propagation and potential amplification of uncertainty in a process chain (Type I to III robust designs across process chains). In this paper, we introduce a variation to the existing goal-oriented inverse decision-based design method to bring in robustness for multiple conflicting goals from the stand-point of Type I to III robust design across process chains. The variation embodies the introduction of specific robust design goals and constraints anchored in the mathematical constructs of error margin indices and design capability indices to determine “satisficing robust design” specifications for given performance requirement ranges using the goal-oriented, inverse design method. The design of a hot rolling process chain for the production of a rod is used as an example.

A Goal-Oriented, Sequential, Inverse Design Method for the Horizontal Integration of a Multistage Hot Rod Rolling System

2017 ◽  
Vol 139 (3) ◽  
Author(s):  
Anand Balu Nellippallil ◽  
Kevin N. Song ◽  
Chung-Hyun Goh ◽  
Pramod Zagade ◽  
B. P. Gautham ◽  
...  
Keyword(s):  
Information Flow ◽  
Design Method ◽  
Inverse Design ◽  
Process Chain ◽  
Horizontal Integration ◽  
Rolling System ◽  
Design Variables ◽  
First Pass ◽  
Rod Rolling ◽  
Inverse Design Method

The steel manufacturing process is characterized by the requirement of expeditious development of high quality products at low cost through the effective use of available resources. Identifying solutions that meet the conflicting commercially imperative goals of such process chains is hard using traditional search techniques. The complexity in such a problem increases due to the presence of a large number of design variables, constraints and bounds, conflicting goals and the complex sequential relationships of the different stages of manufacturing. A classic example of such a manufacturing problem is the design of a rolling system for manufacturing a steel rod. This is a sequential process in which information flows from first rolling stage/pass to the last rolling pass and the decisions made at first pass influence the decisions that are made at the later passes. In this context, we define horizontal integration as the facilitation of information flow from one stage to another thereby establishing the integration of manufacturing stages to realize the end product. In this paper, we present an inverse design method based on well-established empirical models and response surface models developed through simulation experiments (finite-element based) along with the compromise decision support problem (cDSP) construct to support integrated information flow across different stages of a multistage hot rod rolling system. The method is goal-oriented because the design decisions are first made based on the end requirements identified for the process at the last rolling pass and these decisions are then passed to the preceding rolling passes following the sequential order in an inverse manner to design the entire rolling process chain to achieve the horizontal integration of stages. We illustrate the efficacy of the method by carrying out the design of a multistage rolling system. We formulate the cDSP for the second and fourth pass of a four pass rolling chain. The stages are designed by sequentially passing the design information obtained after exercising the cDSP for the last pass for different scenarios and identifying the best combination of design variables that satisfies the conflicting goals. The cDSP for the second pass helps in integrated information flow from fourth to first pass and in meeting specified goals imposed by the fourth and third passes. The end goals identified for this problem for the fourth pass are minimization of ovality (quality) of rod, maximization of throughput (productivity), and minimization of rolling load (performance and cost). The method can be instantiated for other multistage manufacturing processes such as the steel making process chain having several unit operations.

scholarly journals Structural Optimization Considering Flexibility. (Integrated Design Method for Compliant Mechanisms).

1998 ◽  
Vol 41 (3) ◽  
pp. 476-484 ◽  
Author(s):  
Shinji NISHIWAKI ◽  
MIN Seungjae ◽  
Susumu EJIMA ◽  
Noboru KIKUCHI
Keyword(s):  
Structural Optimization ◽  
Compliant Mechanisms ◽  
Design Method ◽  
Integrated Design

An Integrated Design Optimization Approach for Quantitative and Qualitative Search Space

2003 ◽  
Author(s):  
Victor Oduguwa ◽  
Rajkumar Roy ◽  
Didier Farrugia
Keyword(s):  
Real World ◽  
Design Problem ◽  
Integrated Design ◽  
Search Space ◽  
Optimization Approach ◽  
Design Optimisation ◽  
Solution Approach ◽  
Rod Rolling ◽  
Algorithmic Engineering ◽  
Real World Problems

Most of the algorithmic engineering design optimisation approaches reported in the literature aims to find the best set of solutions within a quantitative (QT) search space of the given problem while ignoring related qualitative (QL) issues. These QL issues can be very important and by ignoring them in the optimisation search, can have expensive consequences especially for real world problems. This paper presents a new integrated design optimisation approach for QT and QL search space. The proposed solution approach is based on design of experiment methods and fuzzy logic principles for building the required QL models, and evolutionary multi-objective optimisation technique for solving the design problem. The proposed technique was applied to a two objectives rod rolling problem. The results obtained demonstrate that the proposed solution approach can be used to solve real world problems taking into account the related QL evaluation of the design problem.

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