Development of a Finite Element Data Exchange System for chain simulation of manufacturing processes

A Finite Element Data Exchange System (FEDES) is developed to transfer and map finite element analysis (FEA) data between different FE solvers and meshes. Six commercial FE codes (ABAQUS, ANSYS, DEFORM, MSC.MARC, MORFEO and VULCAN) are incorporated in FEDES. Four mapping techniques are developed and embedded in FEDES which allow the data mapping between meshes with different element types and densities. The algorithms of the mapping techniques are described and compared for 2D and 3D models. The design and capabilities of FEDES are also described. Results from the data transfer and mapping between different FE simulations are presented and discussed. Two manufacturing chains are simulated using FEDES in this paper. The first manufacturing chain is simulated on a parallelepiped geometry including casting, forging and heat treatment processes. The second manufacturing chain is simulated on an aero-engine vane component including metal deposition, welding, heat treatment, machining and shot-peening processes. The development of FEDES demonstrates an integrated simulation platform for modelling manufacturing chains of processes using different FE solvers and meshes.