DIAS was launched in June 2020 and had a Digital Kick Off meeting with the Topic Leader (GKN Aerospace). An automated digital simulation and experimentation framework has been developed, that allow a range of definition, simulation and post processing tools to address weld manufacturability of advanced jet engine structural components together with performance evaluation for range of varying design parameters. Fraunhofer FCC developed algorithms to enable weld path evaluation for candidate designs, Chalmers have generated architectural models Enhance Functions Means Models, and generative geometrical modes in CAD that support a wide range of design parameters for a typical turbine structure of an jet engine. Cambridge have developed interactive decision support for the results processing, including developing ability to take results from E FM studies, via Design Structure Matrices, into the Cambridge Advanced Modeller where further analysis, learning and visualisation of results are provided.
The ability to integrate directly welding manufacturability into a conceptual design loop, with up to 1000 alternative geometrical designs are assesses simultaneously together with mechanical, cost and weight evaluation advances state of the art and the first results have been published and demonstrated publicly at the ICED (International Conference on Engineering Design) in August 2021. Thereafter the ability to include weld distortion of variable welding parameters were included, as well as increased degree of automation and integration. Functions Means modelling together with Change Propagation enabled quantified risk analysis, combining simulation results with non-physical factors such as supplier readiness was added. The use of AI/Machine Learning was used to strenghthen the interactive and visual decisionmaking. The completeness and fidelity of the industrial case situation The resulting DIAS methodology and its components has been validated together with the topic lead to validate functionality and initiate exploitation. In short the key results can be listed as a system and methodology for digital design experiments that included the integration of
-Validated and idealized weld distortion assessment simulation methods,
-Assessment of non-physics based factors in evaluation of concepts
-Weld accessibility by simulation robot welding equipment and process variation parameters
-Interactive Decision Making including Machine learning
-Quantified risk analysis based on results
-Architectural and functions means modelling combining product and manufacturing alternatives
The results have been validated with the topic leaders specialists, and training have been conducted. Generalized results have been used in PhD courses. Key results have been disseminated into design research communities, aeroengine communities, aircraft manufacturing communities and contributed to electric hybrid aircraft roadmaps in Europe. Methods developed have been integrated into research based tools, commercial tools as well as demonstrated how the methodology can be exploited in a company environment .
In summary, DIAS have demonstrated how manufacturability of welding can be included in digital simulation based design experiments to optimise concurrently product and manufacturing processes. This reduce the risk to invest and integrate novel technologies by conducting robust design studies including factors not until now being possible to include in design.
