Selecting materials at an early product design stage
ENGINEERING DESIGN Selecting materials at an early product ROUNDTABLES design stage | Arlindo Silva March 17, 2015 Selecting materials at an early product design stage tools and methods Arlindo Silva et al. Instituto Superior Tecnico University of Lisbon, Portugal March 17, 2015 Instituto Superior Técnico 1 Selecting materials at an early product design stage | Arlindo Silva Outline • The materials selection problem • Materials screening: an example on natural fiber composites • Optimization: an example from the automotive industry • Integration: an example from the aeronautics industry • Conclusions and final remarks March 17, 2015 Instituto Superior Técnico 2 Selecting materials at an early product design stage | Arlindo Silva March 17, 2015 Instituto Superior Técnico 3 Selecting materials at an early product design stage | Arlindo Silva March 17, 2015 Instituto Superior Técnico 4 Selecting materials at an early product design stage | Arlindo Silva March 17, 2015 Instituto Superior Técnico 5 Selecting materials at an early product design stage | Arlindo Silva March 17, 2015 Instituto Superior Técnico 6 Selecting materials at an early product design stage | Arlindo Silva The materials selection problem • Innovation requires innovative thinking and new applications for new (or old) materials • Today, a designer can pick between ~160,000 different materials • But how? March 17, 2015 Instituto Superior Técnico 7 Selecting materials at an early product design stage | Arlindo Silva • Structured methods are mostly in use (Ashby procedure, MADM, whatever worked before,…) • This presentation will be about MADM March 17, 2015 Instituto Superior Técnico 8 Selecting materials at an early product design stage | Arlindo Silva Common themes for the case studies • Data – Method – Visualization • The result is never a single material, but a map of possible materials to help the designer make informed decisions March 17, 2015 Instituto Superior Técnico 9 Selecting materials at an early product design stage | Arlindo Silva Materials screening: an example on natural fiber composites What is the hypothetically best combination of natural fiber and bio-resin for a structural composite panel? – Naturally depends on the function – …but some requirements are pervasive! – Specific strength and stiffness, weight, cost,… March 17, 2015 Instituto Superior Técnico 10 Selecting materials at an early product design stage | Arlindo Silva Data, data, data! March 17, 2015 Instituto Superior Técnico 11 Selecting materials at an early product design stage | Arlindo Silva March 17, 2015 Instituto Superior Técnico 12 Selecting materials at an early product design stage | Arlindo Silva March 17, 2015 Instituto Superior Técnico 13 Selecting materials at an early product design stage | Arlindo Silva March 17, 2015 Instituto Superior Técnico 14 Selecting materials at an early product design stage | Arlindo Silva What about a composite with 30%Vf? March 17, 2015 Instituto Superior Técnico 15 Selecting materials at an early product design stage | Arlindo Silva Optimization: an example from industry Is optimizing each part of a large set of parts the same as optimizing the set globally? – Generally not => look for global optimum – Again, the global optimum depends on the requirements for that set of parts March 17, 2015 Instituto Superior Técnico 16 Selecting materials at an early product design stage | Arlindo Silva Small stampings for automobiles • Stiffness or strength enforced at the absolute minimum cost (and/or weight) • Take into account: – Manufacturability proxies (FLD) – Simplified design models – Stamping cost models – Economies of scale March 17, 2015 Instituto Superior Técnico 17 Selecting materials at an early product design stage | Arlindo Silva Baseline scenario: Part grade Thickness 1 7 0.85 2 8 0.9 3 23 0.6 4 14 0.75 5 18 1 6 12 1.5 7 26 1.4 … … … Part number • Set of 55 small stampings • 36 different steel grades • 26 different material thicknesses Come up with an “optimized” set for weight, manufacturing costs, and materials acquisition costs March 17, 2015 Material Instituto Superior Técnico 18 Selecting materials at an early product design stage | Arlindo Silva Generate new vector The procedure: No • Use Direct Multi Search Optimization – Derivative-free – Capable of handling the discrete design variables Design model Accept? Iterates • Generate and evaluate alternative sets and build a Pareto front Baseline solution Yes Objective function Technical cost model Pareto dominance Material cost model Pareto front DMS March 17, 2015 Instituto Superior Técnico 19 Selecting materials at an early product design stage | Arlindo Silva Sets on the Pareto front after X iterations: 1.15 36 1.1 37 38 39 1.05 40 Normalized result 41 42 43 1 44 45 46 0.95 47 48 0.9 Man. Cost Acq. cost Set Weight Objective functions March 17, 2015 Instituto Superior Técnico 20 Selecting materials at an early product design stage | Arlindo Silva Sets on the Pareto front after X iterations: 1.15 19 158 182 1.1 Normalized result 1.05 1 0.95 0.9 Man. Cost March 17, 2015 Acq. cost Objective functions Instituto Superior Técnico Set Weight 21 Selecting materials at an early product design stage | Arlindo Silva Integration: an example from the aeronautics industry Selection of composite materials considering cost and environmental factors without neglecting structural performance! March 17, 2015 Instituto Superior Técnico 25 Selecting materials at an early product design stage | Arlindo Silva Challenge for the designer: – – – – Variety of materials per layer Organization of the layers Orientation of each layer # iterations required to meet design requirements March 17, 2015 Instituto Superior Técnico 26 Selecting materials at an early product design stage | Arlindo Silva Market need Problem Statement Conceptual Preliminary Detail • • • Possible solutions Candidate materials Possible Layups • • • Short list of possible solutions More specific material prop. FE Analysis • • • Working drawings Refined cost estimates Coupon Testing Prototyping *Adapted from Aceves (2008) March 17, 2015 Production Instituto Superior Técnico 27 Selecting materials at an early product design stage | Arlindo Silva Main Objective of the Research Environmental Performance (Eco Audit Module) Indicators: EI99, total energy consumption, recyclability etc. Material Selection Interface Indicators: stiffness, weight, buckling, crashworthiness etc. March 17, 2015 Economic Performance (PBCM Module) Technical Performance (FEM Module) Instituto Superior Técnico Indicators: max. gross margin, min. investment cost etc. 28 Selecting materials at an early product design stage | Arlindo Silva FEM Module Part and ProcessCost Description Generate new vector No PBCM Module Verify Const’s Yes Eco Audit Module Objective Function Calculation Iteration Pareto Dominance Pareto Front Selecting materials at an early product design stage | Arlindo Silva Run DMS f1(x) DMS Optimizer Objective: min f1(x), min f2(x) new iteration Check domina nce f1,f2 Pareto front file (.txt) x1 x2 x3 x4 x5 x6 x7 x8 x9 x10 Calculate Fabrication Cost f2(x) Nastran output file (.f06) Cost Model (.xlsx) Nastran input file (.bdf) Run Nastran f1(x) = total fabrication cost f2(x) = displacement (R1) x1-x8 = Orientations (0, +45, -45, 90) x9 = Material type (1, 2, 3) x10 = Number of layers (1-8) Selecting materials at an early product design stage | Arlindo Silva Pre-processor: MSC Patran 2014 Solver: MSC Nastran 2014 MODEL DEFINITION: • • • • L:1000mm, W:1000mm flat plate The laminate can be up to16 symmetric plies with equal thickness. The plies have four orientations: 0, +45, -45 and 90 degrees. The plate is fixed along one end and supported vertically in one of the other two corners. • The plate is loaded with a uniform pressure of 0.1k Pa, giving a total force of 100 Newton on the plate. Selecting materials at an early product design stage | Arlindo Silva Flat Plate Material Types # Material Name Desciption 1 CC 206 ET 445 43% 2 3 Tensile Poisson's Modulus ratio In-Plane Shear Modulus Unit Cost Thickness PREPREG Carbon/ Epoxy 27,87 € 0,25 61900 0,06 3100 CC 284 ER 440 48% PREPREG Carbon/ Epoxy 39,30 € 0,3 57100 0,06 3070 CC 600 ET 445 S 38 % PREPREG Carbon/ Epoxy 42,36 € 0,6 61400 0,06 4590 Selecting materials at an early product design stage | Arlindo Silva Mold Production Cutting Lamination Finishing Demolding Curing Reverse Engineering & Quality Selecting materials at an early product design stage | Arlindo Silva 5,00 Displacement (f1) 4,00 3,00 2,00 1,00 0,00 0 200 400 600 800 Total Fabrication Cost (f2) 1000 1200 Selecting materials at an early product design stage | Arlindo Silva Conclusions • Selecting materials is a complex, engineering systems problem • Its implications in a real context are still not fully grasped • Further research with advanced optimization tools can help March 17, 2015 Instituto Superior Técnico 35 Selecting materials at an early product design stage | Arlindo Silva Credits to: • Profs. Mihail Fontul, Elsa Henriques, Marco Leite, Inês Ribeiro and Paulo Peças (IST), and José Madeira (IPL) • Dr. Richard Roth (MIT) • Dr. Georgios Koronis (former PhD student, IST) • Elçin Calado (PhD student, IST) March 17, 2015 Instituto Superior Técnico 36 ENGINEERING DESIGN Selecting materials at an early product ROUNDTABLES design stage | Arlindo Silva March 17, 2015 Selecting materials at an early product design stage tools and methods Arlindo Silva et al. Instituto Superior Tecnico University of Lisbon, Portugal [email protected] March 17, 2015 Instituto Superior Técnico 37
© Copyright 2024