Multiscale Design Background and Motivation

Transcription

1 Multiscale Design Background and Motivation Learning Objectives Investigate the role of materials design in the context of multiscale design. Compare three methods of incorporating materials in product design. Speculate how materials design will affect product design in Key Points from Lecture 24 on Robust Design Quality, Robustness, and Taguchi s Philosophy Type I ~ IV Robust Design Example: 1 Drink Design Robust Materials Design

2 Outline Context Materials Design in the Context of Multiscale Design Motivation, Definition, and Example Materials Design History, Current Uses, and Goals Materials in Product Design Material-Driven Design Material Selection Materials Design Comparison of Methods Materials Design Answering the Q4S Materials Design and P&B 2

3 Question for the Semester We imagine a future in which geographically distributed engineers collaboratively develop, build, and test solutions to design-manufacture problems encountered in the product realization process. We recognize that solutions evolve over time. Accordingly, we expect you to build on what has been done before. In this context, we want you to provide a method to support the realization of products for a global marketplace through distributed design and manufacture. How should the P&B systematic design method be personalized and augmented to support the realization of products for a global marketplace in a distributed environment? ======== Personalized made usable for realizing all types of systems Augmented made usable for designing for a global marketplace and a distributed environment 3

4 Steps to Answer the Q4S 4 Part 1 Describe your world of 2020 Part 2 Understand your world of today Part 3 In the context of the preceding postulate your method; one that you will be able to evolve into the methods required in your world of 2020

5 Scaffolding to Answer the Q4S Internalize P&B (A1) Critically evaluate answers to the Q4S proposed by others (A2) Identify the characteristics of the world of 2020 and the requirements list for your method for 2020 (A2) Learn how to verify your personalized and augmented method for 2020 (A3) Identify a base method plus verification strategy for your answer to the Q4S and a method for verification (A4, Mid- Term) Develop the base method you have identified to meet the requirements for the method (A5 A7) Postulate how you will design sustainable engineering systems for a global marketplace. (Answer to Q4S) 5

6 The Big Picture Get you to Understand the importance of understanding the problem. Understand the importance of identifying the drivers for solving the problem. Understand the difference between a solution to a well defined problem with one in which there is randomness. Understand the importance of strategy in problem solving. Recognize the importance of people in relation to the technology that is available for solving the problems. Speculate about the World of 2020 and abstract the requirements list for P&B Deep read P&B and abstract (reverse engineer) the requirements list. Key Learn how to create new knowledge through abstraction 6

7 Lecture Schedule Lecture 21 (11-2) Mass Customization Lecture 22 (11-3) Design for X Lecture 23 (11-9) Designing Customizable Products and Processes Lecture 24 (11-10) Robust Design Lecture 25 (11-16) Multiscale Design Background and Motivation Lecture 26 (11-17) Multiscale Design Examples Learning Objectives for Lectures 25-26: Materials design in the context of multiscale design Application of multiscale design materials design techniques in product design examples Materials design in your augmented P&B and in the world of

8 Material Selection in P&B Information: Adapt the requirements list Task Market, company, economy Plan and clarify the task: Analyze the market and the company situation Find and select product ideas Formulate a product proposal Clarify the task Elaborate a requirements list Requirements list (Design specification) Develop the principle solution: Identify essential problems Establish function structures Search for working principles and working structures Combine and firm up into concept variants Evaluate against technical and economic criteria Concept (Principle Solution) Develop the construction structure: Preliminary form design, material selection and calculation Select best preliminary layouts Refine and improve layouts Evaluate against technical and economic criteria Preliminary layout Define the construction structure: Eliminate weak spots Check for errors, disturbing influences and minimum costs Prepare the preliminary parts list and production and assembly documents Definitive layout Prepare production and operating documents: Elaborate detail drawings and parts lists Complete production, assembly, transport, and operating instructions Check all documents Product Documentation Solution Phase 1: Planning and clarifying Phase 2: Conceptual design Phase 3: Embodiment design Phase 4: Detail design Material selection in original P&B Phase 3: Embodiment Design Concept (Principal Solution) Develop the construction structure: Preliminary form design, material selection and calculation Select best preliminary layouts Refine and improve layouts Evaluate against technical and economic criteria Preliminary layout 8

9 Outline 9 Context Materials Design in the Context of Multiscale Design Motivation, Definition, and Example Materials Design History, Current Uses, and Goals Materials in Product Design Material-Driven Design Material Selection Materials Design Comparison of Methods Materials Design Answering the Q4S Materials Design and P&B

10 10 Multiscale Design REDUCED ORDER MODELS Mesostructure Microstructure Nanostructure Seepersad, C. C., 2004, A Robust Topological Preliminary Design Exploration Method with Materials Design Applications, Ph.D. Dissertation, G. W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA.

11 Materials Design Example Consider a simple example Say that you are designing a sandwich. You plan to add many items in your sandwich. Therefore, you decide that the bread must be particularly strong. You also would like to design a healthy bread using whole grains. Product Sandwich Material Bread Material Requirements Strong bread, whole grains Requirements Building Blocks Processing Material Product 11 Materials Design

12 12 Definition of Materials Design from Class??

13 Materials Design Definition Materials design is the process of tailoring material properties to meet the requirements of specific design problems *. Tailoring material properties Materials can be tailored or adapted to produce new materials with specific properties and performance levels. Requirements Material requirements detail the minimum material performance level necessary for a successful product design. Design problems Materials are incorporated in all product design problems. *Seepersad, C. C., 2004, A Robust Topological Preliminary Design Exploration Method with Materials Design Applications, Ph.D. Dissertation, G. W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA. 13

14 Why is Materials Design Important? Engineers are able to design application-specific materials Many current materials cannot meet complex or multifunctional design requirements Shape Memory Insulator Low Cost Material Requirements Low Density Low Thermal Expansion Magnetic Water-Resistant 14 High Thermal Conductivity High E

15 Outline 15 Context Materials Design in the Context of Multiscale Design Motivation, Definition, and Example Materials Design History, Current Uses, and Goals Materials in Product Design Material-Driven Design Material Selection Materials Design Comparison of Methods Materials Design Answering the Q4S Materials Design and P&B

16 Materials Design History New materials have been discovered for centuries The impact of new materials on civilization is evident in the naming of historical periods: Stone Age, Bronze Age, Iron Age, Silicon Age Metal Alloys Metallic materials made form tow or more metals Examples: stainless steel, brass, bronze Composites Materials made of two or more components Examples: concrete, plywood, foam 16 Polymers Repeated elements joined by chemical bonds Examples: plastics

17 Materials Design Current Uses Linear Cellular Alloys Seepersad, C. C., 2004, A Robust Topological Preliminary Design Exploration Method with Materials Design Applications, Ph.D. Dissertation, G. W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA. Rapid Manufacturing p?id=123&oper=show&rubriek_id=10 db/faststoff/felt_eng.shtml 17 Functionally Graded Materials Shear stress distribution in the carotid artery

18 18 Materials Design Goals Processing Structure Property Performance Deductive Approach (Material Scientists) Inductive Approach (Designers) Olson, G. B., 1997, Computational Design of Hierarchically Structured Materials, Science, Vol. 277, No. 5330, pp

19 Materials Design Goals Manufacturing Processes Manufacturing processes used to create a material will affect the material microstructure Material microstructure is dependant on factors such as: Processing temperature Chemical reactions Processing Structure Property Performance Material Microstructure Material microstructure is determined by: Chemical elements Element size Element location Size and position of voids Dislocations (cracks, voids) Material Properties Material properties include values you can find in a table, such as: Density Elastic Modulus Thermal Conductivity Magnetism Texture 19 Material Performance Material performance is the behavior of a material under specific loading conditions Material performance can be described as: Strain distribution Temperature change Plastic deformation

20 Outline 20 Context Materials Design in the Context of Multiscale Design Motivation, Definition, and Example Materials Design History, Current Uses, and Goals Materials in Product Design Material-Driven Design Material Selection Materials Design Comparison of Methods Materials Design Answering the Q4S Materials Design and P&B

21 Material-Driven Design Material-driven design describes a paradigm of incorporating materials in product designs. Materials are chosen based on availability, familiarity, or previous success. Materials are not tailor-made to meet specific design requirements. Product Material Product Requirements Design Process Product Layout / Dimensions 21 Product dimensions are directly linked to product material For fixed load conditions, product material determine product dimensions Material-Driven Design Material Selection Material Design

22 Material-Driven Design Example Consider a blacksmith in the Middle Ages designing a knight s sword. The sword will be made using iron. The sword must not fail under certain loading conditions. The length and cross-section of the sword are determined by the material, loading conditions, and overall geometry. Iron Not fail Design Process Cross-Section Length 22 Material-Driven Design Material Selection Material Design

23 Material Selection Material selection is a method of using a vast material database for selecting the best materials for product designs. The material selection method is the textbook Materials Selection in Mechanical Design by Michael F. Ashby. Product Requirements Material Database Design Process Product Layout / Dimensions Product Material 23 Product dimensions influence product material Product material is not determined until late in the design process Material-Driven Design Material Selection Material Design

24 Material Selection Method for material selection in product design as detailed in Materials Selection in Mechanical Design, by Michael F. Ashby All Materials Screening: apply property limits Ranking: apply material indices Subset of Materials Supporting information: handbooks, specialized software, expert systems, www Prime Candidates Local Conditions Final Material Choice Ashby, Materials Selection in Mechanical Design, 2 nd Ed, pg. 67. Material-Driven Design Material Selection Material Design 24

25 Material Selection The preliminary selection DSP and selection DSP can be used throughout the material selection process. Preliminary Selection DSP Selection DSP All Materials Screening: apply property limits Ranking: apply material indices Subset of Materials Supporting information: handbooks, specialized software, expert systems, www Prime Candidates Local Conditions Final Material Choice Ashby, Materials Selection in Mechanical Design, 2 nd Ed, pg. 67. Material-Driven Design Material Selection Material Design 25

26 Material Selection Screening materials based on Ashby s textbook Materials Selection in Mechanical Design 1. Identify the property limits imposed by the product design. For example, consider that you are designing a component of a water heater. The product must be able to perform well at high temperatures. You determine that the fracture strength of the part must be 100 MPa at 200 C. Look at a material graph of: Strength of Material as f(temperature) vs. Temperature 26 Material-Driven Design Material Selection Material Design

27 Material Selection Screening materials based Feasible on Ashby s Design Space textbook Materials Selection in Mechanical Feasible Design Space 1. Identify the property limits imposed by the product design. For example, consider that you are designing a component of a water heater. The product must be able to perform well at high temperatures. You determine that the fracture strength of the part must be 100 MPa at 200 C. Look at a material graph of: Strength of Material as f(temperature) vs. Temperature 27 Material-Driven Design Material Selection Material Design

28 Material Selection Ranking materials based on Ashby s textbook Materials Selection in Mechanical Design 2. Identify the form (basic geometry) of the part. Cantilever? Shaft? Gear? What s the cross-section? 3. Detail the function (load requirements) of the part. What loading conditions will the part experience? 4. Write objective function(s). What do you want to maximize/minimize? Part weight? Deflection? Cost? Size? 5. Develop material index based on loading conditions and objective function(s). 6. Use material property charts to identify and rank a subset of possible materials. 28 Material-Driven Design Material Selection Material Design

29 29 Material Selection Density, ρ (Mg/m 3 ) Young s Modulus, E (GPa) Material-Driven Design Material Selection Material Design

30 Material Selection vs. Materials Design 30 Back to our bread baking example Material Selection Materials Design Material Database Building Blocks Alternatives Material Processing Material Material-Driven Design Material Selection Material Design

31 Materials Design Materials design is developing and constructing materials with specific qualities to meet design requirements. New materials are only limited by available elements, physical laws, and chemical laws. Design freedom is maintained later in the design process. Product Requirements Product Layout / Dimensions Design Process Product Material Product Layout / Dimensions 31 Product dimensions are input or output parameters set by the designer There is a weak coupling between product material and geometry Material-Driven Design Material Selection Material Design

32 Comparison of Methods Material-Driven Design Material Selection Materials Design Product Material Product Requirements Product Requirements Material Database Product Requirements Product Layout / Dimensions Design Process Design Process Design Process Product Layout / Dimensions Product Layout / Dimensions Product Material Product Material Product Layout / Dimensions 32 Product dimensions are directly linked to product material For fixed load conditions, product material determine product dimensions Product dimensions influence product material Product material is not determined until late in the design process Product dimensions are input or output parameters set by the designer There is a weak coupling between product material and geometry Material-Driven Design Material Selection Material Design

33 Outline 33 Context Materials Design in the Context of Multiscale Design Motivation, Definition, and Example Materials Design History, Current Uses, and Goals Materials in Product Design Material-Driven Design Material Selection Materials Design Comparison of Methods Materials Design Answering the Q4S Materials Design and P&B

34 Answering the Q4S Information: Adapt the requirements list LE.2 Task Market, company, economy Plan and clarify the task: Analyze the market and the company situation Find and select product ideas Formulate a product proposal Clarify the task Elaborate a requirements list Requirements list (Design specification) Develop the principle solution: Identify essential problems Establish function structures Search for working principles and working structures Combine and firm up into concept variants Evaluate against technical and economic criteria Concept (Principle Solution) Develop the construction structure: Preliminary form design, material selection and calculation Select best preliminary layouts Refine and improve layouts Evaluate against technical and economic criteria Preliminary layout Define the construction structure: Eliminate weak spots Check for errors, disturbing influences and minimum costs Prepare the preliminary parts list and production and assembly documents Definitive layout Prepare production and operating documents: Elaborate detail drawings and parts lists Complete production, assembly, transport, and operating instructions Check all documents Product Documentation Solution Phase 1: Planning and clarifying Phase 2: Conceptual design Phase 3: Embodiment design Phase 4: Detail design LE.1 Develop a systematic design process for designing new materials. When should materials be designed? Can we develop a design process for creating a variety of baked goods? When should we bake bread instead of buying bread from the grocery store? Develop simulation tools model and design new materials. Reduce time and cost of designing new materials. How can we reduce bread-baking time? 34

35 Answering the Q4S 35 LE.3 Inductive Approach Investigate relationship between material property and material structure Structure Property Performance Deductive Approach What is the relationship between baking ingredients and bread properties? Processing LE.4 Robust design method for materials design Model uncertainty and error propagation between various length scales How can we design bread that is robust to change?

36 Outline 36 Context Materials Design in the Context of Multiscale Design Motivation, Definition, and Example Materials Design History, Current Uses, and Goals Materials in Product Design Material-Driven Design Material Selection Materials Design Comparison of Methods Materials Design Answering the Q4S Materials Design and P&B

37 Learning Essay Themes LE.1 LE.2 LE.3 LE.4 Speculate the influence and importance of materials in the world of 2020 What are the drivers of designing new materials? Where should material selection / materials design be added to P&B? How can a designer choose between material selection and materials design? What design tools are necessary for materials design? What is the role of materials design in the multiscale product design process? How do we incorporate robustness in the materials design process? 37

38 Material Selection in P&B Information: Adapt the requirements list Task Market, company, economy Plan and clarify the task: Analyze the market and the company situation Find and select product ideas Formulate a product proposal Clarify the task Elaborate a requirements list Requirements list (Design specification) Develop the principle solution: Identify essential problems Establish function structures Search for working principles and working structures Combine and firm up into concept variants Evaluate against technical and economic criteria Concept (Principle Solution) Develop the construction structure: Preliminary form design, material selection and calculation Select best preliminary layouts Refine and improve layouts Evaluate against technical and economic criteria Preliminary layout Define the construction structure: Eliminate weak spots Check for errors, disturbing influences and minimum costs Prepare the preliminary parts list and production and assembly documents Definitive layout Prepare production and operating documents: Elaborate detail drawings and parts lists Complete production, assembly, transport, and operating instructions Check all documents Product Documentation Solution Phase 1: Planning and clarifying Phase 2: Conceptual design Phase 3: Embodiment design Phase 4: Detail design Concept (Principal Solution) Develop the construction structure: Preliminary form design, material selection and calculation Select best preliminary layouts Refine and improve layouts Evaluate against technical and economic criteria Preliminary layout 38 Material selection in original P&B Phase 3: Embodiment Design

39 Key References Ashby, M. F., 1999, Materials Selection in Mechanical Design, Butterworth-Heinemann, Oxford, UK. Olson, G. B., 1997, Computational Design of Hierarchically Structured Materials, Science, Vol. 277, No. 5330, pp Olson, G. B., 2000, Designing a New Materials World, Science, Vol. 288, No. 5468, pp Seepersad, C. C., 2004, A Robust Topological Preliminary Design Exploration Method with Materials Design Applications, Ph.D. Dissertation, G. W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA. 39