As-Manufactured Part Performance: Impact of Residual Stresses

Historically manufacturing variability has been considered as a noise factor due to limited insights about manufacturing history and its influence on part performance. With improvement in computational power and enhancements in commercial simulation tools, it is now feasible to study the influence of manufacturing process on product life in addition to manufacturability. This study demonstrates the concept of as manufactured part performance prediction utilizing forming simulation software to capture deformed geometry along with residual stresses and its integration to performance simulation tool using sheet drawing operation. Simulation predictions are verified and validated with available experimental data.

This approach helps to visualize the variation in part performance with respect to manufacturing process change including process sequence, process parameters and tooling design change. It further helps to create integrated digital model enabling design optimization thereby reducing product cycle time and physical trials.