CORDIS - EU research results

Virtual engineering for robust manufacturing with design integration

Final Report Summary - VERDI (Virtual engineering for robust manufacturing with design integration)

VERDI was a research project with strong focus on the development of the numerical framework for manufacturing process simulations enabling fabrication of structural components, such as fan/compressor and turbine structures. By means of certain information technology and engineering models, numerical process simulation tools in aero-engine development and support would be used in product development and production planning, from the early design to the final design phase. This enabled manufacturing methods to be designed into the component.

To validate the manufacturing process simulation models and the tools for manufacturing process chain simulations developed within VERDI, two components were manufactured. One component represented a rear-engine structure in the nickel-based superalloy, namely Alloy 718; the other component represented a front-engine structure in the titanium alloy Ti-6V-4Al.

The project included manufacturing process modelling development and validation for eight different processes. The process modelling development was made in conjunction with material modelling to handle the temperature ranges, temperature rates, strain and strain rates. Further activities pertained to running process models in virtual manufacturing chains, where different software and space discretisations did not constitute an obstacle.

The main project objectives were the following:
- development of multi-scale process simulation tools for metal deposition, welding, heat treatment, surface strain hardening and machining;
- integration of process simulation tools;
- integration of process simulation and design;
- integration of process simulation and manufacturing;
- implementation of manufacturing simulation in the European aero-engine industry

Amongst the main achievements were the following:
- the capability to carry out virtual manufacturing chains with eight different manufacturing processes on two aerospace materials and the tackle of problems such as different space discretisations, different locations of the engineers and different software;
- validated tools for eight manufacturing processes;
- the capability to carry out virtual evaluations on stability and robustness for all implemented manufacturing processes;
- the capability to carry out component life predictions, including residual states from virtual manufacturing