Reverse Engineering for Cast Foundry Parts

**Reverse Engineering for Cast Foundry Parts**: - Réf **ABG-125700** - Sujet de Thèse- 06/09/2024- Contrat doctoral- Arts et Métiers Institute of Technology, campus d'Aix-en-Provence- Lieu de travail- Aix-en-Provence - Provence-Alpes-Côte d'Azur - France- Intitulé du sujet- Reverse Engineering for Cast Foundry Parts- Champs scientifiques- Sciences de l’ingénieur - Génie des procédés - Mots clés- Reverse engineering, digital twins, cast foundry, Design for Re-Manufacturing, additive manufacturing**Description du sujet**: For many years, casting has largely remained a process with no significant breakthroughs, where lack of innovation stemmed from the profound reliance on empirical knowledge. Processes are typically shaped by the practical expertise of founders and workers, resulting in methods that may be less robust and slower to evolve. Despite these challenges, casting processes are still used for the production of complex shapes, which remains highly relevant to the modern manufacturing in shaping the future. Among the traditional hurdles, one of the current issues is the the reindustrialization of old foundry parts, some of which have long lifespans (> 40 years in aeronautics for example); in this case, previous casting tools are now obsolete and lack available documentation for their re-industrialization. - Proposing a global approach for rapid reverse engineering and digital remanufacturing of casting parts; - Leveraging 3D scanning, additive manufacturing and digital simulations to enhance the foundry process; - Creating digital twins to be fully consistent with scanned or produced casting parts; - Developing a robust tool for iterative modeling based on a Design For Re-Manufacturing (DFRM) approach. The revolution currently taking place towards a digital foundry thanks to the coupling of additive manufacturing technologies (direct 3D printing of sand molds), automated sand shell molding (controlled pressure furnaces) and proactive and multi-scale metrology, opens up prospects for creating digital twins reconstituted from foundry parts. **Specific goals**: Many key tasks for the definition of an overall framework for a “3D Scan to 3D Cast” methodological approach could include: - The development of an approach for the 3D reconstruction of casting parts from multiple sources (industrial drawings, laser scans, tomography); this will produce a 3D model suitable for 3D printing molds and structured for digital simulation of the foundry process. The organization, structuring and configuration of the 3D model must allow rapid iterations of modifications to the shape in connection with the results of digital simulations. - The integration of the previous 3D reconstruction approach into the digital chain of the foundry process (digital simulation of elementary foundry-filling processes, thermal analysis, solidification, etc.) and in the physical chain of material/3D printed mold interaction. - Experimental and numerical predictive validation of this instrumented low-pressure casting methodology, in order to identify the design principles (rules) and in particular the geometries to avoid, based on product/process interactions and defect causes. **Prise de fonction**: - 01/10/2024**Nature du financement**: - Contrat doctoral**Précisions sur le financement**: **Présentation établissement et labo d'accueil**: - Arts et Métiers Institute of Technology, campus d'Aix-en-Provence**About ENSAM AIX-EN-PROVENCE**: **About the LISPEN lab** - System engineering & digital representation - Simulation and control of systems - Human-System Interaction - Industrial transformation **About MSMP** Created in early 2013, the “Mechanics, Surfaces and Materials Processing” (MSMP) laboratory is the result of the merger of the MécaSurf Laboratory in Aix-en-Provence, the LMPF in Châlons-en-Champagne and the teacher-researchers of the “Mechanics, Materials, Processes” department in Lille. The MSMP Laboratory brings together research activities on the 3 Arts et Métiers Paris Tech sites around mechanics, surfaces and interfaces, materials and manufacturing processes. The MSMP-EA7350 laboratory is multi-site (Aix-en-Provence, Châlons-en-Champagne, Lille) and fully integrated into ENSAM and leads its transatlantic partnership with TEES-TAMU/USA for the industry of the future. It develops a multidisciplinary research activity in the field of materials and manufacturing processes. **Site web**: **Intitulé du doctorat**: **Pays d'obtention du doctorat**: - France**Etablissement délivrant le doctorat**: - ECOLE NATIONALE SUPERIEURE DES ARTS ET METIERS**Ecole doctorale**: - Sciences pour l'Ingénieur - SMI- A master’s degree in Mechanical Engineering, Civil Engineering, Materials Science, or other related fields (M2, school of engineer) with solid knowledge in CAD, 3D modeling, reverse engineering and finite element analysis. Knowledge in surveying methods, manufacturing process, metallic materi