Case study of a thermally-assisted manufacturing tool-and-process modeling for design optimization

Abstract

Thermally assisted manufacturing processes require specific tool and process design that is tailored to undertake thermo-fluid dynamics and part variation. Therefore, most of the tooling designs for such processes start at the solid model but then rely heavily on best practices and experience. To allow for a level of flexibility against variations, an automatic controller is added to monitor and adjust the process. However, controllers are only effective as long as the tool and the process have been optimally designed. The challenge in a thermally assisted process stems from the appropriateness of the design of the solid part that is utilized to apply the thermal energy to materials being processed. This process involves thermo-fluid dynamics influencing the solid part shape and performance, while adapting to variations in material and process parameters. This variation of processed parts increases significantly when these parts are nonmetal, like fiberglass and polymers. Additional challenges come from the competitive nature of the thermal processing business resulting in scarcity of related literature.The purpose of this case study was to present a methodology for modeling a thermal tool used in a thermally assisted manufacturing process and the thermo-fluid dynamics associated with this tool in operation, for design optimization that will generate the desired product while accommodating normal process and material variation. In this paper, a thermal tool and process are modeled using a hybrid of solid modeling and thermo-fluid dynamics modeling. The resulting model is experimentally calibrated and tested to predict the performance of the tool and process. Results show a very close match between the simulation and experimental data. The model is further implemented to modify the design and results show very close match between the simulation and actual data.