Manufacturing processes involve complex interaction of physical phenomena such as fluid flow, heat transfer, elastoplastic deformation and stresses, and solid- and liquid-state transformation of materials. One way to understand the complex interaction of all these phenomena is to develop mathematical models of these processes. Developing these multi-physics process models is not very easy. But once developed, such models are extremely valuable for manufacturing process design, product development, and process parameter optimization. Using these models one can predict the possibilities of part defects and failure, determine production cycle time, and perform process and product planning without spending a lot of money on physical prototypes.
Over the past fifteen years I have worked on modeling a variety of manufacturing processes such as casting, welding, heat treatment, laser forming, electro-chemical and electro-discharge machining, etc. These models were developed using a finite element based numerical approach. The results predicted from these models were validated using experimental data. In this poster presentation I plan to use some of the examples from my work to provide an overview of my efforts to understand the complex physical phenomena that occur in manufacturing processes.