June 15, 2014
June 15, 2014
June 18, 2014
24.524.1 - 24.524.10
Enhancing Manufacturing Process Education via Computer Simulation and VisualizationIndustrially significant metal manufacturing processes such as melting, casting, rolling, forging,machining and forming are multi-stage, complex and labor, time and capital intensive processes.Mathematical modeling of these processes provides a theoretical framework for understandingthe process variables and their effects on productivity and quality. However it is usually difficultto provide the students with hands-on experience of experimentation with process parameters toarrive at optical process design. In order to solve this problem, interdisciplinary student projectswere undertaken at author’s institution to develop computer simulation tools that would facilitateprocess visualization, experimentation, exploration, design and optimization.The first system described in this paper is the visualization of production schedule in anindustrial setting that provides a basis for interactive decisions. A metal ingot casting issimulated by designing the abstract machine models to visualize capacity and loading of theproduction schedule. The graphical user interface is created to visualize the schedule accordingto the specific characteristics of the machines. The application of computer tools may also beextended to support other important functionalities such as tracking availability of raw materials,projection of inventory due to production overage, as well as critical business analysis. Thestudents thus are exposed to the comprehensive process analysis. Another example of processsimulation presented in this paper is the design and analysis of flexible rolling technology inindustrial processing of C – Mn and Low C - microalloyed steels. Process simulation toolsdesigned by the students allow new process sequences to be generated by breaking down existingprocess routes in to key elements and then by recombining them to generate novel alternativeand more efficient hot processing sequences. This enables the identification of an optimalprocess sequence for specified steel compositions that also satisfies simultaneous design criteriasuch as process feasibility and property maximization.It is proposed that incorporation of such computer simulation tools in the pedagogy would behighly effective to enhancing and enriching undergraduate manufacturing education.
Manohar, P., & Acharya, S., & Wu, P. Y. (2014, June), Enhancing Manufacturing Process Education via Computer Simulation and Visualization Paper presented at 2014 ASEE Annual Conference & Exposition, Indianapolis, Indiana. https://peer.asee.org/20416
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