Utilizing manufacturing process simulation tools as instructional aids

Abstract

Engineering numerical analysis software has been utilized in design of manufacturing processes, parts or tooling by major manufacturing companies. These tools have become available to smaller companies with the advents in computers. Even though cost of most software is still much greater than cost of a computer with great capacity, software involvement is becoming more and more common in manufacturing design process. On the contrary, cost is not an issue for academic institutions since many software companies have educational programs offering drastic price reductions. This study presents a general manufacturing process course utilizing manufacturing process simulation tools as instructional aids. The objective of the course is to accomplish intelligent use of the software tools in learning design of parts, processes or tooling. Basics of numerical analysis methods, upon which the software are based, are also taught in the proposed course. With the assistance of these tools, students can visualize and better study the manufacturing processes. Issues such as cycle time, load and power requirements, material flow, solidification, thermal management, parts' defects and quality, or structural state of tooling and tool life can be well understood. The authors discuss commonly used software tools, their methods of analysis, and their possible utilization in undergraduate and/or graduate level manufacturing course environments. Computer laboratory examples are presented to convey the importance of simulation in manufacturing process design. The study is completed after a specific look at die-casting process analysis through two different tools and methods, finite difference method (FDM) and geometric visualization, and their role in understanding the process.