NSF Grant Number: DMI- 0113295 PI: Prof. Nicholas Zabaras Institution: Cornell University Title: Development of a robust computational design simulator for industrial deformation processes

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NSF Grant Number DMI- 0113295PI Prof. Nicholas
Zabaras Institution Cornell UniversityTitle
Development of a robust computational design
simulator for industrial deformation processes
Research Objectives To develop a mathematically
and computationally rigorous gradient-based
optimization methodology for virtual materials
process design that is based on quantified
product quality and accounts for process targets
and constraints including economic aspects.

• Future research
• Multiscale metal forming design with reduced
  order modeling of microstructure
• Design of formed products with desired
  directional microstructure dependent properties
• Probabilistic design using spectral methods with
  specification of robustness limits in the design
  variables

• Current capabilities
• Development of a general purpose continuum
  sensitivity method for the design of multi-stage
  industrial deformation processes
• Deformation process design for porous materials
• Design of 3D realistic preforms and dies
• Extension to polycrystal plasticity based
  constitutive models with evolution of
  crystallographic texture

Design for desired yield stress at a material
point
Normalized yield stress
Macro - continuum
Micro-scale
Polycrystal plasticity
Broader Impact A virtual laboratory for
realistic materials process design is developed
that will lead to reduction in lead time for
process development, trimming the cost of an
extensive experimental trial-and-error process
development effort, developing processes for
tailored material properties and increasing
volume/time yield. The design simulator under
development provides a robust and handy
industrial tool to carry out real-time metal
forming design.
Initial guess Optimal preform




(Minimal barreling)
Materials Process Design and Control Laboratory,
Cornell University