Simulations for Integrated Product Realization 7.5 credits

The course covers the use of powerful simulation tools to optimise manufacturing processes and develop sustainable, high-quality products. Students will explore simulations of various manufacturing processes, including metal casting and plastic injection moulding, to predict material properties and other effects of the process on the manufactured parts. These effects are then integrated into FEM simulations of the part in use. The use of Design of Experiments and optimization techniques to optimize the part geometry and process variables are explored. With a strong industry connection, the course includes a project where students apply their knowledge to real-world manufacturing challenges. Examples are drawn from industrial manufacturing processes, with a particular focus on metal casting and polymer injection moulding. The course includes the following elements: - Simulation of manufacturing processes, with a particular focus on casting and polymer injection moulding - Introduction to modelling and simulation of flow, microstructure formation and prediction of mechanical properties and residual stresses - Optimization of geometry and process parameters for high-quality manufacturing and minimisation of defects - Modelling and simulation of multiphysics problems