Integrated Computational Materials Engineering A Transformational Discipline for Improved Competitiveness and National Security (2008) / Chapter Skim
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2 Case Studies and Lessons Learned
2 Case Studies and Lessons Learned
Pages 36-66
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From page 36... ...
In a large, multidisciplinary engineering environment, an integrated product development team (IPDT) -- that is, the group of stakeholders Michael Winter, P&W, "Infrastructure, processes, implementation and utilization of computational tools in the design process," Presentation to the committee on March 13, 2007.
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From page 37... ...
For example, a modern gas turbine engine has 80,000 sep arate parts and 5,000 separate part numbers,1 including 200 major components requiring three-dimensional computer-aided engineering (CAE) analysis with structural finite element and computational fluid dynamics codes.
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From page 38... ...
SOURCE: Michael Winter, P&W, "Infrastructure, processes, implementation and utilization of computational tools in the design process," Presentation to the committee on March 13, 2007. Available at http://www7.nationalacademies.org/nmab/CICME_Mtg_Presentations.html.
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From page 39... ...
The flow through this figure shows the individual steps involved in establishing the computational process. Adapted from Michael Winter, P&W, "Infrastructure, processes, implementation and utiliza tion of computational tools in the design process," Presentation to the committee on March 13, 2007.
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. FIGURE 2-2-1 Boeing's integration of analytical tools for design of hypersonic vehicles.
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From page 41... ...
A materials analysis is not part of this process. SOURCE: Kevin Bowcutt, Boeing.
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From page 42... ...
The goal of AIM was to establish an ICME tool set, integrate materials analysis with design engineering, and demonstrate the benefit of ICME in terms of reduced materials development time and cost. In that same time frame, similar efforts were launched in other industrial sectors to improve product performance and provide information that would be impossible or extremely costly to obtain using experimental methods. In general, case studies reviewed by the committee demonstrate that while ICME is still an emerging discipline it can nevertheless provide significant benefits, such as lower costs and shorter cycle times for component design and process development, lower manufacturing costs, and improved prognosis of the subsys tem component life.
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From page 43... ...
The committee identified similar examples in nonmetallic systems such as polymers and semiconductors, but they either lacked any detailed information on ROI or did not approach full ICME integration. For example, in the area of integrated circuits, models for dielectric constants, electromigration, dislocation generation, and barrier layer adhesion have not yet been integrated with CAD circuit design models or "equipment" models for lithography or processing., The committee notes, therefore, that while the examples shown in this report all involve metallic systems, it believes that ICME will be applicable and will demonstrate significant benefits for integrating materials, component design, and manufacturing processes across all materials regimes, including nanomaterials, biological materials, polymeric materials, ceramics, functional materials and composites.
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From page 44... ...
Fully funded by Ford to address specific power-train components, the VAC methodology was implemented by the company for cast aluminum power-train component design, manufacturing, and CAE. As discussed below, VAC has resulted in millions of dollars in direct savings and cost avoidance.
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From page 45... ...
Substantial effort was applied to developing efficient links between the output of the casting modeling and structure and property prediction tools to feed seamlessly into the FEA codes and to facilitate reorganization of the design process. Figure 2-2 shows the process flow for predicting the influence of the casting and heat treatment process on the spatial distribution of yield strength in a typi
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From page 46... ...
Finally, these microstructural quantities are used to predict the manufacturing history sensitive, spatial distributions in yield strength. Specific commercial codes and Ford-developed programs and subroutines that have been integrated into the process are identified at each step.
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From page 47... ...
allow for full component design improvements by adjusting both the manufacturing process variables and the component dimensions. Although limited manual optimization of the manufacturing process and product geometry is feasible, computational limitations preclude full multiattribute optimization.
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The VAC technology is projected to have saved Ford up to $100 million in cost avoidance by resolving product issues and between $2 million and $5 million per year in reduced testing requirements and reduced development time, providing an estimated combined ROI of well over 7:1.,,10 These achievements would not have been possible without both the upfront investment in ICME tool development and the acceptance of a change to the manufacturing culture associated with modifying the design analysis to allow the results of manufacturing simulations of the component to be used as inputs to the component life predictions. VAC was initially developed for a single alloy system.
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From page 49... ...
Integrating Materials, Component Design, and Manufacturing Processes in the Aerospace Sector The DARPA AIM program is another example of an effort to integrate material properties in the design and manufacturing optimization process. As depicted in Figure 2-4, when the program was initiated in 2001, the materials discipline was not yet integrated into the turbine engine design stream.
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From page 50... ...
and the manufacturing process (material properties) , requiring the integration of commercially available engineering analysis codes and material behavior models developed at universities.
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Case Study 3 represents the full application of ICME in the design process and shows that system-level performance can be substantially improved over the current state of the art. Integrating Materials, Component Design, and Manufacturing Processes: Other Examples Other examples of integrating materials, component design, and manufacturing processes can be found in Table 2-1, along with their corresponding benefits.
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From page 52... ...
General Electric Company/ Accelerated Insertion of Potential 50 percent reduction P&W/Boeing Materials in development time, potential eightfold reduction in testing, potential improvement in component capability Livermore Software Technology Use of stamping CAE output Enabled use of advanced high Corporation/ESI Group/Ford as material property input strength steels in body structures (separate studies) for crash CAE in automotive for significant weight savings structures Naval Surface Warfare Center Development of an Accelerated Development in progress; Insertion of Materials system optimization of thermomechanical for an aluminum extrusion history of AA6082 during the extrusion of sidewall panels for a littoral combatant ship Knolls Atomic Power Fracture of high-strength Optimization of critical embrittling/ Laboratory (Lockheed Martin superalloys in nuclear industry strengthening impurities Corporation)
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From page 53... ...
To support this effort, the National Nuclear Security Administration (NNSA) of the DOE sponsored a program to provide predictions of primary-stage pit lifetimes owing to plutonium aging.
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From page 54... ...
methodology to assess pit lifetimes based on simulations of primary performance. Age-dependent models derived from data, science-based computational methods, and conservative assumptions were used to calculate the change in pit lifetime owing to the change in material properties.
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commercial codes are now widely used for process modeling, the incorporation of microstructure evolution in these simulations is relatively new, indeed in its infancy in terms of commercialization. For the early adopters, there exists the potential for improving yields, reducing cycle time and energy costs, and optimizing a process for a given material or desired structure.
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From page 56... ...
"process recipe" is an annealing cycle that reduces the time and energy requirements involved in the spheroidization heat treatments applied to 52100 and other homogeneous high-carbon steels. The recipe has been perfected and implemented, reducing the process cycle time 33-50 percent and energy costs by $500,000 per year.
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From page 57... ...
While this area of integrated materials and manufacturing promises to provide the most immediate benefits to industry, it must be recognized that additional development and validation remains for these new techniques to be more widely utilized. LESSONS LEARNED FROM OTHER DISCIPLINES In addition to investigating the current status of ICME, the committee also explored some major integration efforts in other scientific and engineering fields.
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From page 58... ...
In the following sections specific lessons learned from the genomics, bioinformatics, and astronomy com munities are highlighted. Genomics and Bioinformatics One of the most significant integration efforts in modern science was the human genome project (HGP)
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From page 59... ...
Although HGP was completed in 2003, NIH continues to fund major coordinated sequencing projects. As an example of the magnitude and type of efforts funded by NIH, the sequence of the Rhesus monkey was recently completed, the result of a $20 million effort involving 100 researchers that was approved in 2005.21 While the resources expected to be made available to ICME are likely to be fewer than were applied to mapping the human genome, there are significant lessons to be learned by the ICME community from HGP by considering how that community initially organized and set goals and by considering the potential impact of large-scale, coordinated projects based on the gathering and organization of data.
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From page 60... ...
The HGP also drove developments in bioinformatics, a field that lies at the intersection of biology, computer science, and information science and is defined by the NIH as "research, development, or application of computational tools and approaches for expanding the use of biological, medical, behavioral or health data, including those to acquire, store, organize, archive, analyze, or visualize such data." Bioinformatics generally makes use of publicly available databases that can be mined for associating complex disorders (analogous to material proper ties) with different versions of the same gene (analogous to microstructures)
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From page 61... ...
An effort on the part of the emerging ICME community to set quantitative and specific goals for materials characterization, databases, computational models, and training will be needed for this discipline to mature. 25 For more information see http://www.ncbi.nlm.nih.gov/.
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From page 62... ...
The Sloan Digital Sky Survey provides over 40 terabytes (TB) of raw data and 5 TB of process catalogs to the public.
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From page 63... ...
Performance, cost, and schedule benefits drive the increasing use of simulation. ICME shows promise for decreasing component design and process development costs and cycle time, lowering manufacturing costs, improving material life-cycle prognosis, and ultimately allowing for agile response to changing market demands.
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From page 64... ...
The design philosophy must shift from separating the product design analysis and the manufacturing process optimization. The engineering culture must shift toward increasing confidence in and reliance on computational materials engineer ing models and depending less on databases and physical prototypes.
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From page 65... ...
A number of case studies, both within and outside the materials engineering discipline, highlighted the need for large-scale capture and dissemination of critical data. One showed the negative impact of failing to archive data in a recoverable form.34 To create and utilize accurate and quantitative ICME tools, engineers must have easy access to relevant, high-quality data.
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From page 66... ...
Sensitivity studies, understanding of real-world uncertainty, and experimental validation were key to gaining the acceptance of and value from ICME tools with less than 100 percent accuracy. To judge what is a reasonable balance between efficiency and robustness requires a team with expertise.
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