Lightweight Design for Manufacturing

Experiments need to be performed first to validate the forming technique before launching in the industry. I managed to solve multiple technical problems with my engineering skills. Take an example, I designed a rig utilizing the hydraulic force and validated it with finite element simulation in order to eject the titanium workpiece stuck on the tool with a single trial. It gave the ultimate solution for dealing with the same problem in any other stamping experiments.

Lab experiments continuously cost a large amount of cost. Computer-aided simulation can tremendously reduce that cost. I programmed the code that describes the material behaviour of titanium during deformation and created a FE model to simulate the titanium forming process. The final model shows an accuracy above 80% compared to the experimental result.

The third part of my placement is to design the die set for U-bending experiments to test and reduce the spring-back of the titanium workpiece. I questioned the design of the traditional U-bending die set which wastes too much material for performing only one configuration of experiment. Therefore, I redesigned it so that researchers can perform tasks with more than four configurations with a single die set.