CORDIS provides links to public deliverables and publications of HORIZON projects.
Links to deliverables and publications from FP7 projects, as well as links to some specific result types such as dataset and software, are dynamically retrieved from OpenAIRE .
Exploitable results
Overall open system for the detailed development of castings for manufacture developed by the project based on applications integrated using the DMAC OLE for D&M technology
The PRIDE Hybrid Object Modeller is the integration of the CAD, CAM, CAE & Casting Simulation software modules through the DMAC OLE for D&M geometry and topology interface. This allows a plug and play approach for developers of complex castings and other parts who can choose to take:
- the complete PRIDE HOM solution; or
- individual CAD, CAM, CAE or Casting Simulation programs to match their immediate needs.
- The PRIDE HOM is open and users may integrate third party software that supports the DMAC interface
The PRIDE hybrid object modeller will support:
- detailed modelling of incompletely specified areas, including using data digitized from physical models;
- preparation of related representations for analysis and manufacture;
- adjustment of detailed models to meet performance and manufacturing criteria;
- prototype manufacture for form/fit and performance testing;
- testing and adjustment of design to improve/optimize;
- manufacture of production tooling
The PRIDE Hybrid Object Modeller includes commercial CAD, CAM, CAE and casting simulation packages operating in the Microsoft Windows environment together with the PDE modeller, which is able to generate optimal shapes within parameter driven geometrical and physical constraints. The packages include additional software developed to tackle the bottleneck issues identified by the industrial application experts. They are suitable for use by SME's, who predominate in this area of industry.
The current state of the HOM demonstrates the potential but more development is needed prior to commercial use. The long term application goal is the emerging market for multidisciplinary design optimization (MDO). The medium term application goal is a framework for best in class software components for design and manufacture.
CAD/CAM software enhanced to overcome bottlenecks in the detailed design for manufacture of castings and tooling as well as enabled for integration using the DMAC technology
The detailed engineering of castings requires powerful CAD/CAM applications to minimize the time needed to operate on the complex geometry found in the casting and the tooling. The CAD/CAM Object Application software is based on Delcam's new PowerSHAPE, CopyCAD and PowerMILL software that incorporates the new developments produced during PRIDE in response to the user requirements. Functionality includes:
- Modelling based on a wide range of geometric objects (points, wireframes, surface and solids)
- Able to receive data from a range of data exchange formats
- Able to construct manufacturing features, e.g. fillets and draft surfaces - Able to construct tooling models (core, moulds, core-boxes etc.)
- Able to generate rapid prototyping models
- Able to machine hybrid models
- Uses COM technology to communicate between applications and to third party applications
- Integrates with automatic meshing for CAE and simulation
- Uses PC platform so that it is easy to use and is based on familiar Windows paradigm
The end users of this result are typically SME contractors producing castings and foundry tooling. The software also has the potential to be used for plastic mouldings and mould tools. Many of the features of the software can be used in the short term but some aspects of the hybrid object technology require further development before they can be fully exploited. The software will be disseminated by licensing to end users and OEMs.
FEM/BEM meshing and analysis software enabled for integration using the DMAC technology.
The detailed design of a casting or moulding may require the use of CAE technology to achieve a good design. The CAE object application was developed by CETIM based on their CASTOR FEM/BEM software. This has been adapted to work under Windows NT and a new mesh pre-processor has been developed to produce mesh composed of 3D elements. 3D elements are generated automatically from the CAD model. The CAD model geometry is accessed using the DMAC geometry and topology interface, which is supported by the PRIDE CAD applications and by third party software, e.g. SolidWorks.
The software can be used by a variety of component types, not just for castings. The software will be licensed to end users world-wide. The DMAC geometry and topology interface is a much better method of integrating CAD models with analysis that an IGES or STL file link. However some third party modellers do not fully implement the protocol and until they do so they will not be compatible.
The CAE object application can be used within the PRIDE optimization framework to iterate to a better design. The processing time to solve a problem on realistic part is too long today but the technology trend suggests that this obstacle will disappear in due course.
Modelling of shape based on geometric and physical constraints controlled by a small number of key parameters that can be modified to find a locally optimal value of a chosen measure of merit.
The PDE Method is particularly suited for design optimization because it can efficiently parameterize shape, i.e. represent complex surface geometries in terms of a relatively small set of design variables, particularly when compared with current representational techniques. Studies have been carried out on optimal design in a wide range of areas. e.g. strength (design of shell-like structures, design of mechanical parts), hydrodynamics (design of ship hulls), aerodynamics (design of sub- and supersonic aircraft geometries), heat transfer (design of cooling fins), fluid mechanics (design of cylinder heads for internal combustion engines).
The PDE Object and Optimization Application Software provides an interactive design tool to create PDE models of shapes and to apply parametric handles on the shape. The PDE software is integrated with the other applications in the PRIDE HOM by means of the DMAC OLE for D&M geometry and topology interface. It can be used to produce a representation of a critical detail of the casting in terms of a small number of parameters. The optimization software can then improve the shape for a specified objective function, e.g. adverse pressure gradient, by communicating with a suitable analysis code.
The results of the project have demonstrated the principles of the method. More development is needed before the software can be commercialized. The University of Leeds are pursuing a number of collaborative approaches to further develop and exploit the technology.
Casting simulation meshing and analysis software enabled for integration using the DMAC technology.
Prototype castings are often made using different techniques from production castings due to the cost of tooling and the quantities needed. Quality defects in both cases impact product lead-time, scrap rates and hence energy wastage. Casting simulation software aims to minimize scrap by allowing the casting tooling and process parameters to be tested and improved at the design stage. The ability to use a CAD model of the casting system for analysis with little or no intervention is a major requirement for the widespread use of casting simulation.
The Casting Simulation Object Application Software was developed by RWP based on their SIMTEC code, which was adapted for the Windows NT environment as WinCast. The software is integrated as a component of the PRIDE HOM by using the DMAC geometry and topology interface to generate a 3D volumetric mesh representing the casting system. The casting simulation can be used to predict the process results and aid the improvement of the design of the casting system by the technologist.
The PRIDE project has shown in principle that the Casting Simulation Object Application Software can be used with the optimization tools developed in the project. Current limitations relate to the simulation processing time, which, although acceptable for one or two simulations, is too slow for a large number of iterations. This issue will diminish with the increase in processor power. In the mean time, the benefit of being able to simulate by automatically interrogating the CAD model is a significant benefit.
The software is applicable to casting designers, patternmakers and foundry technologists for both gravity and high-pressure die-casting. It will be exploited by licensing end-users and through sales partners world-wide.
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