Industry Plenary Lecture

Byung Kwan Chun (USA): (Bio)

An Integrated Material-Process Modeling Framework for Multiscale and AI-Augmented Process Design

The demands of modern manufacturing have expanded far beyond traditional forging and metal forming simulation. Recent advances provide modeling capabilities across the entire manufacturing process chain, including post-processing operations such as heat treatment, joining, machining, and shot peening. This enables the prediction of material evolution—such as microstructure, mechanical properties, and residual stresses—throughout the full process, from ingot conversion to final assembly.

This integrated framework advances the state of the art in four key aspects. First, enhanced multi-physics formulations extend conventional rigid plastic models to elasto-plastic, elasto-viscoplastic, and coupled thermo-mechanical, fluid, and electromagnetic analyses, enabling accurate prediction of thermal behavior, material flow, residual stresses, and distortion. Second, hierarchical material modeling bridges phenomenological descriptions with multiscale approaches, effectively capturing phase transformation, microstructure evolution, and anisotropic texture development. Third, computational performance and robustness are improved through parallel computing, GPU acceleration, domain decomposition, and Arbitrary Lagrangian–Eulerian (ALE) methods. Finally, AI-augmented design integrates surrogate modeling to enable near real-time prediction and rapid exploration of process–material design spaces.    

Bart Carleer (Switzerland): (Bio)

Smart Engineering for Smart Manufacturing

Zero failures and zero reworks are a key asset for efficient mass production of stamping parts. In order to achieve this ambitious target, an effective engineering process is required as well as a reliable operations in the press shop. A continuous virtual data flow across all phases in the development process result in aligned quality requirements, early risk visibility and avoidance of late surprises. The smart engineering approach and the insights obtained can be reused in manufacturing. The smart manufacturing approach as a result reduces redundant checks and ensures consistency in the stamping process, this latter can even be automated.