Advanced Computational Techniques for the Design of Deformation Processes

Objectives The objective of this work is to develop a continuum sensitivity finite element analysis for the robust design of multi-stage metal forming processes in aircraft manufacturing. The computational forming design simulator being developed is applied to industrial forming design and provides the means to select the sequence of deformation processes, design the dies and preforms for each process stage as well as the process conditions such that a product is obtained with desired shape and microstructure and with the minimal material utilization and overall cost. This virtual process laboratory will assist the aircraft manufacturing industry in reducing time for process and product development, in trimming the cost of an extensive experimental process development effort and in developing processes for tailored material properties.