The past decade has witnessed the development and initial introduction of various process models through computer simulation. Led by programs sponsored by the USAF, WRDC, Manufacturing Technology Directorate, the first achievement of this effort was the development of the ALPID software and its subsequent application to the extrusion and isothermal forging of superalloy turbine disks for jet aircraft engines. The reliability and accuracy of the evolved models have resulted in more rapid technical response from forging suppliers, improved quality and consistency in the forged product, and lower costs.
Forging models have since been applied to any number of more conventional forging alloys and processes. But, perhaps of more importance to the industry as a whole, these process description and control concepts and disciplines now have also been extended to a wide variety of other material and process applications. When a process model is coupled with computer process control the two synergistically provide a powerful process monitor and a most significant quality control tool.
This paper will review the developmental history of process models for current and proposed process applications as well as show how typical variables interrelate with specific process elements and the capability and payoff of process modeling for these same applications. At the close of the paper, an attempt is made to forecast the direction and scope of future process modeling initiatives.