The role of advanced engineering simulation in model-based design

The agile manufacturing paradigm engenders many new concepts and work approaches for manufacturing operations. A technology often invoked in the concept of agility is modeling and simulation. Few would disagree that modeling and simulation holds the potential to substantially reduce the product development cycle and lead to improve product reliability and performance. Advanced engineering simulation can impact manufacturing in three areas: process design, product design, and process control. However, despite that promise, the routine utilization of modeling and simulation by industry within the design process is very limited. Advanced simulation is still used primarily in a troubleshooting mode examining design or process problems after the fact. Sandia National Laboratories has been engaged in the development of advanced engineering simulation tools for many years and more recently has begun to focus on the application of such models to manufacturing processes important for the defense industry. These efforts involve considerable interaction and cooperative research with US industry. Based upon this experience, this presentation examines the elements that are necessary for advanced engineering simulation to become an integral part of the design process

Development and Validation of Energy Simulation for Additive Manufacturing

Additive manufacturing (AM) is a promising manufacturing technology towards cleaner production systems. Nevertheless, recent studies state that environmental benefits of AM are case-specific and need to be evaluated and confirmed in the design phase. To enable the energy performance evaluation in the design phase, developing convenient tools for energy prediction of AM has been an important research task. Aiming at this problem, this paper presents the research for energy modeling, simulation implementation, and experimental validation of an energy simulation tool of two AM processes: Selective laser melting (SLM) and Fused deposition modeling (FDM). The developed simulation tool can be conveniently used for energy consumption quantification and evaluation during the product and process design for AM

Coal conversion systems design and process modeling. Volume 1: Application of MPPR and Aspen computer models

The development of a coal gasification system design and mass and energy balance simulation program for the TVA and other similar facilities is described. The materials-process-product model (MPPM) and the advanced system for process engineering (ASPEN) computer program were selected from available steady state and dynamic models. The MPPM was selected to serve as the basis for development of system level design model structure because it provided the capability for process block material and energy balance and high-level systems sizing and costing. The ASPEN simulation serves as the basis for assessing detailed component models for the system design modeling program. The ASPEN components were analyzed to identify particular process blocks and data packages (physical properties) which could be extracted and used in the system design modeling program. While ASPEN physical properties calculation routines are capable of generating physical properties required for process simulation, not all required physical property data are available, and must be user-entered

IMPACT OF 3D SIMULATION MODELING ON ARCHITECTURAL DESIGN EDUCATION

Throughout the last few decades, architectural design education has witnessed several changes. One of these changes was using 3D Simulation modeling technology into design process. With the rise of environmental approach in design, new 3D simulation applications started to invade studios and laboratories of design. These applications proved an obvious efficiency for the architectural form concerning thermal adaptation, ideal lighting, and most appropriate ventilation. Lately, Arabic countries imported this technology into its schools of architecture, but unfortunately students faced obstacles in applying it in their design projects. Although there are certain courses, such as; \u27Environmental Design\u27, \u27Indoor Environmental Control\u27, and \u27Digital Fabrication Modeling\u27, that already give students a good knowledge with 3D simulation modeling and environment aspects, but in fact students still find difficulties in applying it into their \u27Architectural Design\u27 course. This paper investigates the real reasons standing behind this problem trying to produce new suggestions that can be followed into design studio. That aims to improve the student\u27s architectural product to be closer to reality. As an effective case study, the paper will examine the impact of using 3D simulation modeling on a selection of design projects from \u27the fourth year students, Faculty of Architectural Engineering, Beirut Arab University, Lebanon\u27. One of the important findings is: \u27Students consider the 3D simulation modeling a constrain reducing their conceptual creativity\u27

Coupled fluid-thermal analysis of low-pressure sublimation and condensation with application to freeze-drying

Freeze-drying is a low-pressure, low-temperature condensation pumping process widely used in the manufacture of bio-pharmaceuticals for removal of solvents by sublimation. The goal of the process is to provide a stable dosage form by removing the solvent in such a way that the sensitive molecular structure of the active substance is least disturbed. The vacuum environment presents unique challenges for understanding and controlling heat and mass transfer in the process. As a result, the design of equipment and associated processes has been largely empirical, slow and inefficient.^ A comprehensive simulation framework to predict both, process and equipment performance is critical to improve current practice. A part of the dissertation is aimed at performing coupled fluid-thermal analysis of low-pressure sublimation-condensation processes typical of freeze-drying technologies. Both, experimental and computational models are used to first understand the key heat transfer modes during the process. A modeling and computational framework, validated with experiments for analysis of sublimation, water-vapor flow and condensation in application to pharmaceutical freeze-drying is developed.^ Augmented with computational fluid dynamics modeling, the simulation framework presented here allows to predict for the first time, dynamic product/process conditions taking into consideration specifics of equipment design. Moreover, by applying the modeling framework to process design based on a design-space approach, it has demonstrated that there is a viable alternative to empiricism

ECUT (Energy Conversion and Utilization Technologies) program: Biocatalysis Project

Fiscal year 1987 research activities and accomplishments for the Biocatalysis Project of the U.S. Department of Energy, Energy Conversion and Utilization Technologies (ECUT) Division are presented. The project's technical activities were organized into three work elements. The Molecular Modeling and Applied Genetics work element includes modeling and simulation studies to verify a dynamic model of the enzyme carboxypeptidase; plasmid stabilization by chromosomal integration; growth and stability characteristics of plasmid-containing cells; and determination of optional production parameters for hyper-production of polyphenol oxidase. The Bioprocess Engineering work element supports efforts in novel bioreactor concepts that are likely to lead to substantially higher levels of reactor productivity, product yields, and lower separation energetics. The Bioprocess Design and Assessment work element attempts to develop procedures (via user-friendly computer software) for assessing the economics and energetics of a given biocatalyst process

Methodical procedure for a surrogate model based fatigue calculation to support the design process of eBike drive units

In this paper, a method is developed to consider multiaxial load spectra and their variation in a computationally efficient local fatigue calculation procedure. This method is based on an FE data-based surrogate model and is intended to support the simulation-based product design process. To demonstrate their application and necessity, a case study on the design of eBike drive units is presented. For this purpose, the general requirements for the design of eBike drive units as well as the fundamentals of multiaxial fatigue analysis and surrogate modeling are outlined. In addition, a validation process of the surrogate model and its use for fatigue calculation is presented and discussed

Advances on Mechanics, Design Engineering and Manufacturing III

This open access book gathers contributions presented at the International Joint Conference on Mechanics, Design Engineering and Advanced Manufacturing (JCM 2020), held as a web conference on June 2–4, 2020. It reports on cutting-edge topics in product design and manufacturing, such as industrial methods for integrated product and process design; innovative design; and computer-aided design. Further topics covered include virtual simulation and reverse engineering; additive manufacturing; product manufacturing; engineering methods in medicine and education; representation techniques; and nautical, aeronautics and aerospace design and modeling. The book is organized into four main parts, reflecting the focus and primary themes of the conference. The contributions presented here not only provide researchers, engineers and experts in a range of industrial engineering subfields with extensive information to support their daily work; they are also intended to stimulate new research directions, advanced applications of the methods discussed and future interdisciplinary collaborations

Transforming senior students to Competent Engineers through Project Based Learning

Abstract This paper focus on transforming the senior level engineering students to competent manufacturing engineers thru project based learning. The final project work for the manufacturing system design and simulation (MFGE-440) course is geared toward challenging the students to develop a detailed manufacturing part-process flow, optimize the process layout and develop simulation model to predict the throughput using Arena Simulation Modeling. Each group was given a typical product drawing to develop system design and simulation analysis. The part arrival times, process times, the forklift speed, part transfer times and load/unload times were given. These products require the operations like, saw cutting, drilling, vertical milling, horizontal milling, and final machining operations. The original simulation model predicted 110 parts output for 2000 minutes simulation time. The team analysed various "What-If" scenarios using the computer simulation model to improve the throughput. The revised simulation model produced 159 parts, an improvement of 43%. This team project study demonstrated student's critical thinking, product design skills, machining knowledge, layout skills, processing skills, and simulation modeling skills. This group project not only encouraged the students to work as a team but also encouraged their individual talents to shine. This group project gave students the confidence to handle product from "drawing to production". It was very satisfying to see how these senior students are transforming themselves to competent engineers