Synthesis and Multi-Objective Model-based Optimisation of Process Chains for Manufacturing Components with Functionally Graded Properties

Functional gradation denotes the systematic and reproducible microstructure adjustment of a single material component for the customisation of the macroscopic properties (e.g. hardness or ductility). This customisation is tailored with respect to the later intended application of the component. The improved material utilisation enables light weight design and simplifies the recycling by using single material components. Hence, it provides a resource-conserving alternative for modern composite materials and offers an innovative approach for customisable smart products of the future. Manufacturing functionally graded components requires complex thermo-mechanically coupled process chains that increase the effort for the holistic design. To realise the full potential offered by functional gradation, the available planning and optimisation methods as well as the surrogate models developed during the first research period of the Collaborative Transregional Research Centre (CRC Transregio 30) are significantly enhanced. Furthermore, all the methods and surrogate models as well as the process knowledge obtained by laboratory experiments are consolidated in a comprehensive computer-aided framework to provide a continuous support for the engineer during the planning process. This contribution proposes the methodical foundations within the framework along the planning process: Component description, synthesis of suitable manufacturing process chains, and optimisation of the process chain parameters as well as the specification of the production system. The methods are validated based on an exemplary planning task within the CRC Transregio 30.