During the 47 months of the reporting period from 1 September 2015 to 31 July 2019 (including the 5 months extension), work has been carried out according to the plan. Details of the work and the results are as follows.
Work Package (WP) 1: Manufacturing process simulator
The electromagnetic field of the HEPHAISTOS CA1 MW oven was simulated. The hexagonal oven cavity, alongside the 12 waveguides, was included. Heat flux sensors were also modelled in order for the process simulator to be able to predict the response of these sensors during processing.
The models developed were translated into the first version of the process simulator. The design of the simulator user interface was based on input requirements from the end users, who provided guidelines on how best to simulate the ceramic matrix composite tool in order for the simulator to be used as a design application for the tool (for example, isolate the MW absorbing layer so that the impact of different layer thicknesses can be simulated).
Work Package 2: Materials selection and characterisation
As dielectric measurements was developed, which is able to a) make the measurements at MW frequency (2.45GHz) and at elevated temperature, b) accommodate both liquid and solid MUTs, and c)can make measurements on anisotropic materials such as composites with minimum sample preparation.
Work Package 3: Knowledge transfer from simulation to production
Digital manufacturing organisations (SIMUTOOL being an example) thrive on data and digital information. Simulations produce data and take input CAD models and parameters; modern control systems utilise sensor data and control models, and finally, since everything uses or creates information and data, there is a role required to efficiently manage all this data and to intelligently index and link all this data. An ICT system fulfilling such a role can be termed as a Data-intensive Knowledge Management system (DiKM), which has been developed within SIMUTOOL
Work Package 4: Manufacturing process control
The development and formulation of system identification tools for (a) capturing the MW heating process dynamics and (b) developing a virtual sensor for the (typically unavailable during the manufacturing process) composite part temperature, were carried out. The developed tools based on data obtained from the SIMUTOOL simulator was validated and assessed. The selection of tools required for formulation of the SIMUTOOL temperature control algorithm was carried out and integrated into process simulator.
Work Package 5: Manufacturing process design
Materials selection for the tool manufacturing has been carried out, which was then used to manufacture a tool where the bulk material is moderately transparent to MW whereas the tool surface was finished with a MW absorbing material to create a uniform heat distribution within the tool.
Work Package 6: Implementation and Demonstration
The tools/moulds developed in WP5 was utilised to manufacture complex geometries in the MW oven for both aerospace and automotive applications. Successful components were manufactured using MW heating. The power data and the measured temperature data was provided to the simulation team to validate the SIMUTOOL process simulator developed in WP4. The simulation is in good agreement with the experimental data for both aerospace and automotive applications.
Techno-economic analysis has been carried out on the MW tool and MW heating.
Work Package 7: Validation and packaging of toolset
The developed Process simulator, process controller and the knowledge management system has been integrated and packaged for the use of the project partners. The aim is to formulate a new project (SIMUTOOL-phase2), were the simulation platform will be utilised to optimise the microwave oven design, the MW tool/mould material selection and design and finally to optimise the MW heating process for aerospace and automotive industries.
Work Package 8: Exploitation and dissemination
The project consortium started to disseminate and promote the project at trade fairs, exhibitions, conferences, etc., in early 2016. A number of dissemination and exploitation activities have taken place. The project has been presented at twelve conferences and seven trade shows. Five conference papers and three journal papers have been published. More dissemination activities have been planned. One large workshop was held to disseminate the technology for potential users.
