Plenary Lecture

GeoMat: Computer Aided Design by Geometry and Material Science

Professor Paul Xirouchakis
Advanced Manufacturing Systems
Department of Design, Manufacture and Engineering Management
University of Strathclyde
United Kingdom
E-mail: paul.xirouchakis@epfl.ch

Abstract: A new design paradigm based on a geometric-material design modelling approach will be presented that will result in optimized part functionality by simultaneous exploiting geometrical and variable material property degrees of freedom. The expanded design space will provide more opportunities for optimization and will result in new shape-material combinations and a drastically higher optimized customized performance and establish the proposed new design paradigm: Design by Geometry and Material Science. To realize the GeoMat new design paradigm three scientific objectives and methods to achieve them will be presented. The first scientific objective aims to cover the following engineering design challenge: Current CAD systems do not support the modeling of local shape deviations and mechanical properties. Multi-scale modelling approaches will allow the solid modelling both at the bulk and local surface level of a component; this is important since high value components require the simultaneous satisfaction of bulk functional behaviour together with demanding surface properties such as tribological, wear and abrasion resistance. The second scientific objective aims to cover the following engineering design challenge: Current CAD systems do not support the modeling of material gradients and anisotropic properties. The basis will be discussed of introducing new material models within the Multi-scale CAD environment to allow the representation of material properties and anisotropic gradients across multiple scales. This will open the road for the development and application of multi-scale topological optimization methods to result in drastically new component designs satisfying both local and global functional requirements. Within the new GeoMat paradign: Design by Geometry and Material Science the component design will proceed with the intimate collaboration of engineering designers for the macro bulk part behaviour and material science designers for the micro surface part behaviour: the wall of communication between engineering designers and material designers will be broken. The third scientific objective aims to cover both previously identified engineering design challenges by bringing the drastically new GeoMat approaches within the hands of the engineering and material designer. This will require the development of a new formal shape-material language (drastically departing from current shape alone formal languages) so that the designer can interactively work within the new Design by Geometry and Material Science environment. The interactive work will consist in specifying shape and material properties at different scales as well as calling upon topological optimization tools within their CAD environment.

Brief Biography of the Speaker: The focus of Professor Paul Xirouchakis’s research is multidisciplinary at the scientific confluence of design, manufacturing, mechanics, operations research and artificial intelligence:
- Remanufacturing of high value products (molds & dies; oil & gas equipment; diesel engines) using laser metal deposition to reduce lead time, save costs and extend service life
- Laser cutting and repair of CFRP composites based on process development approaches to reduce the heat affected zone and increase productivity
- Zero defect manufacturing using cognitive computation approaches to reduce recast layer thickness and avoid the occurrence of lines & marks in wire Electro-Discharge Machining (EDM) and reduce porosity and micro-cracks in laser metal deposition
- Digital manufacturing for efficient and sustainable milling based on chatter vibrations avoidance to reduce machining time and energy consumption
- Additive manufacturing of aircraft components to realize the Zero Assembly Factory of the Future through component consolidation and topological optimization
- Physics based CAD environment through Medial Axis Transforms to reduce the time to develop a new mechanical product
Professor Paul Xirouchakis was a Professor and Director of the Computer Aided Design and Manufacturing Laboratory at the Swiss Federal Institute of Technology in Lausanne (EPFL) from July 1995 till August 2015. He has 164 international refereed publications and has supervised 21 completed PhD theses. He holds a PhD in Structural Mechanics 1978 from Massachusetts Institute of Technology (MIT), Cambridge, Massachusetts.

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