Course syllabus

Course-PM

IMS160 Digital twins in metals processing lp2 HT24 (7.5 hp)

The course is offered by the Department of Industrial and Materials Science

Contact details

Examiner    Amir Malakizadi (AM), Chalmers       amir.malakizadi@chalmers.se 

Lecturers    Gustav Holmqvist (GH), Chalmers    gustav.holmqvist@chalmers.se

                    Peter Hammersberg (PH), Chalmers peter.hammersberg@chalmers.se

Student administration:  Hanije Safakar, Chalmers   hanije@chalmers.se

Course purpose

The course aims to facilitate advanced manufacturing engineering knowledge regarding modelling and simulation of metal forming, heat treatment, and welding—some of the most value-adding operations in modern manufacturing industries—using commercial software and basic programming. In particular, the course aims at providing in-depth knowledge concerning the relationship between properties and structure of metallic materials with the material processibility and how commercial software tools can facilitate the manufacturing of high-end components with lower costs and improved quality

Schedule

TimeEdit

Course literature

Heat treatment and welding (Books/eBooks):

• Colpaert H. Metallography of steels: interpretation of structure and the effects of processing. ASM International; 2018.
• Lancaster JF. Metallurgy of welding. Elsevier; 1999.
• Totten GE, editor. Handbook of residual stress and deformation of steel. ASM International; 2002.

Forming (Books/eBooks):

• Blazynski TZ. Metal forming: tool profiles and flow, 1976.
• Tschaetsch H. Metal forming practise: processes—machines—tools. Berlin, Heidelberg: Springer Berlin Heidelberg; 2006.
• Hosford WF, Caddell RM. Metal forming: mechanics and metallurgy. Cambridge University Press; 2011.

Course design

The course includes lectures, case studies, tutorials, group assignments and presentations. The course comprises four modules: 1. Fundamentals, 2. Forming, 3. Heat treatment and 4. Welding. Each module includes two weeks of classroom lectures and tutorials. Typical case studies will examine scientific development and industrial end-use of forming, welding and heat treatment processes. The group assignments will form the basis for developing team-based engineering skills needed to solve real manufacturing problems in the industry. Hence, the final (industry) assignment is collaboratively developed in partnership with prominent manufacturing enterprises. The course has no exam; therefore, attendance in lectures (min. 80%) and tutorial exercises (100%) is compulsory. Prior knowledge of MATLAB programming is helpful, but not necessary. A short introduction to MATLAB will be given.

The lectures will be given in English.

The course consists of weekly tutorials on Finite Element Modelling of the forming, heat treatment and welding processes. Reports are to be prepared and handed in for the final industrial assignment through the course home page.

Changes made since the last occasion

The course is newly developed. 

Learning objectives and syllabus

Learning objectives:

• Understand the role of digital twins in sustainable manufacturing and production of high-end components in the automotive and aerospace industries.
• Describe and understand the basic principles of the physics involved in metal forming, heat treatment, and welding processes.
• Assess when advanced simulation tools are necessary and when basic analytical models provide sufficiently reliable results.
• Integrate and apply the material, process, and design knowledge to obtain the desired functionality of manufactured components.
• Demonstrate a basic understanding of how material properties and process design can lead to failure in production and how we can avoid it.
• Understand the source of process and material variations and how digital twins can help to evaluate the outcome.
• Demonstrate the ability to use commercial software and basic programming to address manufacturing challenges. 

Syllabus:

*Participation is compulsory!

** The group assignment will be announced during the course.

Examination form

The grading of the course will be on a basis of 3, 4, and 5. 80% attendance at lectures is required. Attendance and passing of labs/assignments including reports, is a specific requirement of the course to achieve grade 3. To acquire grades 4 and 5, students should attain >60% and >80% of total points from the handed-in quizzes, covering the content of the previous lectures. Additional studies-assignment may be applicable for those students who fail to fulfil the requirements above; these will be consulted individually with the course examiner.