A framework for the computer-aided planning and optimisation of manufacturing processes for components with functional graded properties

Abstract

In this contribution a framework for the computer-aided planning and optimisation of functional graded components is presented. The framework is divided into three modules -the "Component Description", the "Expert System" for the synthetisation of several process chains and the "Modelling and Process Chain Optimisation". The Component Description module enhances a standard computer-aided design (CAD) model by a voxel-based representation of the graded properties. The Expert System synthesises process steps stored in the knowledge base to generate several alternative process chains. Each process chain is capable of producing components according to the enhanced CAD model and usually consists of a sequence of heating-, cooling-, and forming processes. The dependencies between the component and the applied manufacturing processes as well as between the processes themselves need to be considered. The Expert System utilises an ontology for that purpose. The ontology represents all dependencies in a structured way and connects the information of the knowledge base via relations. The third module performs the evaluation of the generated process chains. To accomplish this, the parameters of each process are optimised with respect to the component specification, whereby the result of the best parameterisation is used as representative value. Finally, the process chain which is capable of manufacturing a functionally graded component in an optimal way regarding to the property distributions of the component description is presented by means of a dedicated specification technique.

Planning and optimisation of manufacturing process chains for functionally graded components—part 2: case study on self-reinforced thermoplastic composites

“…For our example, the two cuboids and the angle section were identified. The user of the framework can specify gradients for the whole component, or separate gradients for each feature (2). A gradient always has a name, a description and belongs to a Voxelfeature, as well as to a requirement specified in the Component Requirements step.…”

“…However, the resolution correlates with the computation time and the memory consumption. Once the voxelisation has been started, the progress bar displays the current status of the operation (2). Finally, the voxelised component is displayed (3).…”

“…Initially, the colour scale shows the minimum and maximum values of the gradient provided by the generic Voxelfeature. Once the user has specified the gradient by using the rainbow colour picker (2) or the control panel (3), the model is dyed . The next step of the wizard is the Synthetisation, which is divided into the core process overview shown in Fig.…”

“…The user can select a requirement from a drop-down menu (1) to specify the corresponding minimum and maximum values for the subsequent gradient definition. By means of a radar chart profile [9], all specified requirements are presented to the user (2). The button below the profile opens the legend (3).…”

“…These components are characterised by a continuous distribution of properties over at least one of the three spatial dimensions. They offer a variety of opportunities for sustainable products of the future [2,10].…”