Report of the Workshop Predictive Theoretical, Computational and Experimental Approaches for Additive Manufacturing (WAM 2016) by Xu Guo Gengdong Cheng & Wing-Kam Liu

Author:Xu Guo, Gengdong Cheng & Wing-Kam Liu
Language: eng
Format: epub
Publisher: Springer International Publishing, Cham

Prof. Han noted that AM is a big deal right now at the General Electric Company (GE). There are lots of news since mid-2011. He quoted some statements from GE, for example, “Within our lifetime, at least 50% of the engine will be made by AM”, “In four decades, we could be printing the entire engine”, and “Complexity is free”. For a LEAP fuel nozzle, only one part is manufactured by AM at GE, compared with the traditional manufacturing, which make it 25% lighter and 5x more durable.

Most people are focusing on material and process such as scan strategy, quantifying variability in AM components, and microstructure-aware modeling from materials processing to mechanical performance. However, Prof. Han stated that those are just evolution, not revolution, and that people’s thinking is still in traditional way. When talking about the differences between science and engineering, he raised some issues one should consider, including micro vs. meso vs. macro, material property vs. structure performance, manufacturing processed vs. structure design, and topology vs. sub-surface porous structure. He believes that the meso scale structure is important and simulation of additive design and manufacturing is interesting. He said that the game change includes integration of manufacturing process and field application and combining the modeling process with AM process, and that the behavior in the field application can be tracked back to the manufacturing. The innovation will include new finite element, supper element, implementing the parameters of manufacturing process, such as temperature, size and shape of melting pool, into intuitive equation, big data and knowledge enabling, as well as new methodology and standard for testing and validation, he said.

As for simulation of additive design and manufacturing, Prof. Han proposed some new ways of modeling. One is not dividing an existing structure into finite element but building up the structure by the same path as it is built from AM. Another one is not transferring an existing physical mode to math model but transferring both the physical mode and physical process together into a math model. He emphasized that model building process should be the same as the AM process.

Prof. Han commented that what people need for a structure are reliable design, reliable manufacturing, reliable analysis, reliable test, reliable validation, reliable safety, reliable dependability, and reliable cost. However, so far there have been no tools for design and analysis, no methods for test and validation, no standards for guideline and procedure, and no professionals in this prominent uncultivated land. To be one of the expeditions at Southern University of Science and Technology to explore the dream land, Prof. Han said, he and his collaborators are establishing a new discipline named as “Sub-surface Fine Web Structure Engineering Mechanics”, as shown in Fig. 4.14. It is going to address all four topics of this workshop. Driven by the concrete requirements for a better aero engine, Prof. Han has tried to throw out a brick to attract a jade, as he added.

Fig. 4.14Need for a new discipline. Source Prof. Pinlian Han, Southern University of Science and Technology, presentation of Prof.

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