| Abstract Scope |
In the current state of engineering, manufacturing process design is greatly hampered by the difficulty in predicting and controlling the microstructure of the part and the final property, largely due to the lack of fundamental understanding in the process mechanics and inverse methodologies to determine optimum process parameters. A design framework is developed with direct linkages between Process Path parameters and the final microstructures without resorting to experimentation or FEM. State of the art microstructural design and fabrication methodology is complemented with a multi-scale computational scheme to optimize structure-property relationship. The design framework is based on a digital representation of the microstructure using n-point statistical correlation functions. The framework provides a direct link between the resulting part’s microstructure, mechanical properties, residual stresses, porosity, and distortions. By virtue of the availability of direct mathematical and analytical solutions, the relationships between process parameters and resulting part microstructure and properties will be analytically reversed to yield a non-iterative methodology for machining and additive manufacturing in Al7475 and Ti64 materials. |