Vehicle and Heavy Equipment Integrated Product & Process Development (IPPD) Technology Development: Casting Process Simulation

An overview is presented of the recently proposed Vehicle and Heavy Equipment Integrated Product and Process Development (IPPD) Technology Development project under the Technology Reinvestment Project (TRP) of ARPA. The goals of the tasks proposed in the manufacturing process simulation area are discussed in detail, with particular emphasis on casting. An important aspect envisioned is the integration of OEM's and suppliers within the IPPD environment. It is hoped that the proposed work will significantly benefit steel foundries, and a close collaboration with the SFSA is planned. 1. SUMMARY OF IPPD PROJECT The strategic importance of achieving an Integrated Product and Process Development (IPPD) capability for a broad spectrum of commercial and defense products has been acknowledged. Technological and implementation challenges, however, differ greatly in product sectors such as ground vehicles and equipment, aircraft, microelectronics, and ships. This project focuses specifically on vehicles and heavy equipment, the latter defined broadly as "high capacity self propelled machinery used in military, construction, cargo hauling, material handling, agricultural, and related applications." The simulation based design approach proposed for vehicle and heavy equipment IPPD is shown schematically in Figure 1.1, with a summary of its benefits. The technology to be developed will be integrated with currently isolated CAD, CAE, CAM, and simulation tools to create a revolutionary new development process that uses simulation to rapidly carry out design iterations involving all product and process characteristics.