The Application of Design Rules before Process

Simulation

D J Mynors
Brunel University

Shanghai May 2004

Shanghai May 2004
Material models for IN 718 SPF

See paper 1

Shanghai May 2004

 Web accessible material data
CLIENT SERVER

HTML JSP

‘bean’ Java Object

BROWSER
JAVA
PARSER
SERVLET
Stress
http
response
Strain

XML
http request

Databank
Database

Shanghai May 2004

Shanghai May 2004
 Data and Information Sources
Customer Specification
Quantity, Geometry
Tolerances, Material, µ-structure Materials
Hardness, Quality Production Units
Tolerances
Existing Designs

Design Rules
Engineering Knowledge
• Empirical Designer’s Team • Radii
understanding of metal • Webs
flow • Undercuts
• Understanding of • Holes
material properties • Bosses
• Flash,
• Drafts,
• Ribs
• Narrow_Features
• Parting line

Design Process Loop

(Human Interaction Required at every stage of the
process)
Forging Design

Forgeable Geometry Finishing Die Design

Other Finishing
Operations

Yes
Preform
Preform design Number of stages?
necessary? Costing

No
Final Production
Forging process drawings

Forging Process
No Is forging Yes Parameters and
acceptable? Optimisation
Simulation
Shanghai May 2004
Forging Design

•Shortage of designers

•Lots of repetition

•Look at design office in the

same way as shop floor

•Minimise the design work

•Work in progress !
(See paper 2)

Shanghai May 2004

 Customer Specification Integrated Database and
Quantity, Geometry Information Sources
Tolerances, Material, µ-structure
Hardness, Quality

Materials
Production Units
Tolerances
Existing Designs
Design Rules
Human Interaction With a Model KBE Model • Radii
• Webs
• Undercuts
• Holes
• Bosses
• Flash,
• Drafts,
• Ribs
• Narrow_Features
• Parting line

Design Process Loop

(Human Interaction with a model required only at
certain stages of the process)

Forgeable Geometry Generation Finishing Die Generation Other Finishing Operations

Costing

FEA Model Generation Simulation

Final Production drawings

Yes No
Preform Forging Process Parameters and
Preform Design necessary? Optimisation
Shanghai May 2004
 NURBS Surface and Solids
Geometry Kernel

Design Production
Rules Units
Database Database
GDW

GDL
User Interface

Web Server

DB
Materials
ANSI Client DBMS Database
CL

Existing Application
Designs Database
Database

CAD FEA
package software

Shanghai May 2004

All opinions welcome

Shanghai May 2004