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Simulation Tools for Production Digitalization

 

13 September 2017


DTU Lyngby
Meeting room S9
Anker Engelundsvej 1
2800 Kgs. Lyngby

 

The ongoing digital transformation of industry is changing the future of manufacturing. The implementation of the Industry 4.0 paradigm relies on a complete interconnection between the physical assets through a digital thread, connecting each single phase of the product value chain, from conceptualization to use and disposal. One fundamental element of this transformation is the digital representation through models of the different phases of the product value chain, including part design, manufacturing and assembly. In the future, the development of advanced modelling solutions, in combination with sensors data from processes and systems, is expected to lead to real time modelling as well as real time production optimization and correction. In this context, the seminar aims at presenting the current capabilities and development trends of digital simulation tools applied to the different phases of the product value chain, and specifically in product design, manufacturing process design and assembly process design.

09:00 – 09:30
REGISTRATION & BREAKFAST
09:30 – 09:35
WELCOME
09:35 – 10:10


APPROACHES TO PROCESS SIMULATION IN THE MANUFACTURING INDUSTRY - ESTABLISHING THE DIGITAL TWIN
Jesper Hattel, Professor, DTU

Numerical modelling is increasingly supporting the analysis and optimization of manufacturing processes in the production industry although the acceptance and hence the frequency of use may vary considerably between different branches. Even if being mostly applied to multistep processes, single process steps may be so complex by nature that the needed models to describe them must include multiphysics. On the other hand, processes which inherently may seem multiphysical by nature might sometimes be modelled by considerably simpler models if the problem at hand can be somehow adequately simplified. In the presentation, examples of this as well as coupling to the concept of the digital twin will be presented.

Jesper H. Hattel obtained his M.Sc. in structural engineering in 1989 and his Ph.D. in mechanical engineering in 1993 both from the Technical University of Denmark (DTU). He currently holds a full professorship in modeling of manufacturing processes at the Department of Mechanical Engineering, DTU. His research interests are modeling of processes like casting, joining, composites manufacturing and additive manufacturing. This involves the use of computational methods within the disciplines of heat transfer, fluid dynamics, solid mechanics as well as materials science.
10:10 – 10:45


CURRENT CAPABILITIES OF MULTIPURPOSE SIMULATION SOFTWARE
Kristian Rye Jensen, Sales and Application Engineer, Comsol

Today, simulation is widely used throughout every part of the development and production cycles in order to save time and money by creating and maintaining better products, faster! In this segment, we will give an overview of the current capabilities of multipurpose simulation software with different examples from the chosen field of Additive Manufacturing. The session will end by discussing current trends and future direction.

Kristian Rye Jensen has been a Sales and Applications Engineer at COMSOL's Danish office since 2013. He has a dual MSc degree from the Technical University of Denmark and the Korea Advanced Institute of Science and Technology.
10:45 – 11:05
BREAK
11:05 – 11:40

Anton Jurinic

ADDITIVE MANUFACTURING - CONCEPT TO PRODUCTION THROUGH SIMULATION
Anton Jurinic, Senior Technical Sales Specialist, Dessault Systéms SIMULIA

Additive manufacturing has not only changed the way things are being built, but how they are designed. The adoption of additive manufacturing will continue to rise as manufacturers strive for faster and more reliable throughput from their machines. As the factories of the future become reality, so will the parts that roll out of these machines. We are ready to help our customers succeed in this transformation by ensuring that simulation insight can guide them all the way from concept to design and production.

Anton Jurinic has worked at Dassault Systemés SIMULIA as a Senior Technical Sales Specialist since 2006. Before that he spent almost 20 years in various industries working with FE simulations. He holds a Master of Science in Mechanical Engineering from Chalmers University of Technology in Göteborg
11:40 – 12:15

Sankhya Mohanty

UNLOCKING THE POTENTIAL OF ADDITIVE MANUFACTURING THROUGH SIMULATIONS
Sankhya Mohanty, Post doc, DTU


Additive manufacturing has become a hot topic in both industrial and academic circles in the last five years. The seven families of additive manufacturing processes carry the potential to disrupt and reframe current manufacturing paradigms. Compared to global trends, however, the Danish industry has been slow in harnessing the benefits of these technologies. Simulation tools being developed at DTU can ease the adoption of additive manufacturing technologies into the industrial production lines by providing access to generic process knowledge as well as enabling product- and industry-specific optimized implementation. This talk will highlight a range of simulation tools that extend from those catering to fast, real-time feedback during processing to high-fidelity thermo-microstructural-mechanical simulations for product design and manufacturing process planning.

Sankhya Mohanty draws upon 6 years of experience in additive manufacturing technology and joining processes in performing his tasks at the process modelling group at DTU Mechanical Engineering. Leveraging an equal experience in numerical process modelling with continuing pioneering activities in model-based uncertainty quantification & process optimization, as well as reduced-order model generation, he develops platforms for integrating multi-scale, multi-physics simulation-assisted process planning with additive manufacturing technologies to enable industrial implementation.
12:15 – 13:15
LUNCH
13:15 – 13:50

Mads Jespersen

INJECTION MOULDING PROCESS SIMULATION USING MOLDEX3D
Mads Jespersen, CAE Specialist, FlowHow

Injection simulation has an industrial history of approx. 30 years and is accepted across the plastic industry as a good tool for optimizing plastic parts, moulds and processes. Benefits, capabilities and also limitations within the injection moulding simulation will be part of this presentation. Examples of principle and complex models will be shown and some of my experiences with simulation will be shared.

Mads Jespersen is a mechanical engineer and partner in FlowHow®. Mads has 20 years of experience from the plastic industry with 18 years at LEGO and 2 years at FlowHow®. At FlowHow® he does consultancy based on simulation with moldex3D and sales of Moldex3D.
13:50 – 14:25


SIMULATION OF RESISTANCE WELDING AND MECHANICAL JOINING PROCESSES
Wenqi Zhang, CEO, Swantec

Resistance welding and mechanical joining are commonly used for joining sheet materials and small parts especially in automotive, aerospace, electrical and electronics industry. Continuous developments of new materials with advanced high strength steels (AHSS), aluminum alloys and other lightweight materials have improved the performance of welded structures and products, but also introduced more challenges in welding and joining. In the past three decades, numerical simulation has been more and more widely applied in welding industry worldwide to help engineers create new joining processes and optimize welding process parameters. The latest developments in simulation and optimization of resistance welding, mechanical joining and weld strength testing will be presented with industrial applications.

Dr. Wenqi Zhang received his Ph.D. in Mechanical Engineering from the Technical University of Denmark in 1994 and then continued to work at the same department until 2002 with main focus of research in metal forming, solid state bonding and resistance welding. In 1999, he founded the spin-out company SWANTEC Software and Engineering ApS to commercialize the welding simulation software SORPAS and to continue his research and development on numerical simulation of resistance welding and mechanical joining processes.
14:25 – 14:45
BREAK
14:45 – 15:10


SIMULATIONS AND VIRTUAL REALITY (VR) FOR MANUFACTURING OPTIMIZATION
Ali Ahmad Malik, Ph.D.-student & Frederik Gottlieb, Ph.D., University of Southern Denmark

In their presentation, Ali Malik and Frederik Gottlieb from SDU will present an overview of the current trends and perspectives for the use of virtual reality (VR) in industry. It is a common practice to use virtual simulation for analysis and optimization of manufacturing operations. The simulation tools lack the possibilities to interact with the simulation models in real time environment. However, the immersive VR technologies are making it possible to place the designer in the 3D virtual environment and make real time interactions with the simulation scenario. This can be particularly helpful in human-robot collaborative task planning in developing hybrid assembly systems. Additionally, the visualization quality of simulations can be greatly improved by using game technology.

Ali Ahmad is a learner in the field of digital manufacturing. Currently, he is working as a PhD student within the topic of “Smart Factory: Flexible Lean Automation” at the Mads Clausen Institute at SDU, Sønderborg.

Frederik Gottlieb is a PhD graduate in Design and Entrepreneurship, currently employed as a researcher at the Mads Clausen Institute at SDU in Sønderborg.
15:10 – 15:45


DIGITAL TWINS: CREATING THE DIGITAL ORIGINAL
Anders Lynggaard, Managing Director, Virtual Manufacturing


Products, processes and resources are all equally important candidates for improvement when a production line needs to be developed or optimized. In fact, many important relationships exist between the three domains, even though they are often considered individually. Today, PLM systems can handle the complexity of interrelations between i.e. product features, production equipment and internal logistic issues. This presentation will focus on different methods and tools for successfully allowing project members to collaborate across different domains and develop solutions for complex matters that would otherwise not reveal themselves until installation, at which point delays and costly rework are inevitable.

Since his graduation as a mechanical engineer in 2000, Anders Lynggaard has been working with Manufacturing PLM, Discrete Event- and Robotics Simulations within a wide range of industries, including automotive. Today he is part of the management team in the Swedish based company, Virtual Manufacturing, developing new approaches, tools and services for the manufacturing industry.

15:45 – 15:50
CLOSING REMARKS
Registration fee
Members of ATV-SEMAPP or other promoting organizations: DKK 2,150
Non-members: DKK 2,775
Early bird discount of DKK 200 when registering before 19 August
Ph.D. students at ATV-SEMAPP member institutions: DKK 975
B.Sc. and M.Sc. student members: DKK 200 (student membership is free of charge).

All prices are excluded of Danish VAT.

Registration
Sign up by using this registration form. A confirmation e-mail will be sent to you within a few minutes. Don't forget to check your spam filter, if you don't receive it.

Cancellation 
Cancellations received before 6 September 2017 are fully refunded. No refund for cancellations received on 6 September or later, nor for being unable to attend on the day.

Substitutions are accepted at any time.

Questions 
In case of any questions, please do not hesitate to contact ATV-SEMAPP by e-mailing semapp@atv-semapp.dk or phoning Jytte Laursen +45 4525 4898 or Charlotte Leser +45 4525 4899.

                     

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