TARDEC Product Life Cycle Engineering (PLE) Overview

Transcription

1 U.S. ARMY TANK AUTOMOTIVE RESEARCH, DEVELOPMENT AND ENGINEERING CENTER TARDEC Product Life Cycle Engineering (PLE) Overview September 2017 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited. 1

2 UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited. Organizational Structure US Army Materiel Command (AMC) Assistant Secretary of the Army, Acquisition, Logistics and Technology, ASA (ALT) US Army Research, Development and Engineering Command (RDECOM) US Army TACOM Life Cycle Management Command (LCMC) US Army Training and Doctrine Command (TRADOC) ARL AMRDEC ARDEC CERDEC ECBC NSRDEC TARDEC US Army Tank Automotive Research, Development and Engineering Center (TARDEC) TARDEC is Currently Operationally Aligned (OPCON) to TACOM LCMC While Remaining Administratively Aligned (ADCON) to RDECOM UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited. 2

3 UNCLASSIFIED//FOUO TARDEC s Influential Footprint: Facilities and Workforce TARDEC Main Campus Warren, MI Ground Systems Power and Energy Laboratory (GSPEL) Vehicle Full Load Cooling Test Chamber Crew Station/Turret Motion Base Simulator (CS/TMBS) Ride Motion Simulator System-level Analysis Capability Center for Systems Integration (CSI) Vehicle Characterization Laboratory (VCL) Ground Vehicle Simulation Laboratory (GVSL) Elastomer Improvement Laboratory Fuels & Lubricants Laboratory Various Systems Integration Laboratories (SILs) Active Protection Integration Cell Laser Protection Lab Robotic control Technology Lab Large Platform Autonomy Lab Seawater Desalination Test Facility (SDTF) Port Hueneme, CA FAST- Science Advisor USARPAC, HI Survivability Laboratory Grayling, MI SANGB MI Fresh Water Test Facility Bridge Dynamic Structural Load Simulation Laboratory Occupant Protection Lab Army Petroleum Laboratory New Cumberland, PA ASA(ALT) Washington D.C. SCoE Ft. Lee, VA SOCOM Ft. Bragg, NC 1% 89% 10% Total Workforce Civilians* Military Contractors Total 1825 *Includes Interns 47% 4% Education (Civilians Only) 5% 44% Associates Bachelors Masters Doctorate MSCOE Ft. Leonard Wood, MO Fuels & Lubricants Research Facility San Antonio, TX MCOE Ft. Benning, GA International Presence Australia Germany UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited. 3

4 Overview of PLE Tech Areas Pro-E and AutoCAD Model Generation and Conversion Configuration Management Support and Processes Climate Control & Electrical Tire Engineering Defense Standardization Program Secondary Item Technical Procurement Package Routing Industrial Base/ DMSMS Reverse Engineering Supporting TACOM LCMC, Defense Logistics Agency, TARDEC S&T and PEOs/PMs UNCLASSIFIED / DIST. A 4

5 Overview of PLE Tech Areas (Materials) Materials Application and Integration Evaluation of lightweight materials & technologies Design analysis and optimization for weight reduction Joining Technologies Welding, Adhesives, Bolted Joints Develop requirements for acquisition Evaluate OEM welding process Weld crack analysis Resolve field issues Additive Manufacturing Direct Metal Deposition for reclaiming and repairing of worn and damaged parts Support reverse engineering of parts Coatings & Corrosion Develop Corrosion Prevention Control requirements for acquisition Evaluate, test, and develop solutions for corrosion/coatings issues Evaluation of the fielded fleet for corrosion. Materials Characterization & Failure Analysis Failure analysis and characterization of Metallic and Non-metallic materials. Materials substitution/replacement Testing and qualification of elastomeric materials for track and road wheels Environmental Management Prepare environmental documents (NEPA and PESHE) Eliminate/reduce hazardous materials Execute environmental policy and regulations Coatings & Corrosion Coatings Selection Design Changes for Corrosion Prevention Materials Char. & Failure Analysis Failure Analysis of components Joining Technologies Friction Stir Welding UNCLASSIFIED / DIST. A Environmental Assessments Environmental Elimination of hazardous materials Materials Application & Integration Design Analysis for Weight Reduction Additive Manufacturing Direct Metal Deposition for Worn Parts 5

6 Light-weighting in the Future of Military Ground Vehicles Ground Fleet Must be Expeditionary, Scalable & Ready; a Modern Army Must rapidly deploy to whenever and wherever our national interests are threatened. Must train and equip the Total Army to rapidly deploy, fight, sustain itself, and win against complex state and non-state threats in austere environments and rugged terrain (The expeditionary mindset). Must Focus S&T investment to maximize the potential to use emerging and gamechanging technologies. Lighter combat vehicles with increased lethality, mobility, survivability Lighter, stronger, more fuel efficient support systems Combat vehicle weight drives length of the logistics tail Light Weight Combat Vehicle Science & Technology Campaign (LCVSTC) LCVSTC In 2014, TARDEC led a cross-army coordinated strategy to reduce weight of ground combat vehicles. (Dr. Hitchcock: executive champion) Achieving the Army s goals for light-weight ground vehicles material science non-material science Research is aligned to most promising material and manufacturing opportunities but increased investment in design optimization tools and weight driven metrics will be required to meet aggressive goals Weight reduction is a key enabler for an expeditionary force, but pure materials research is insufficient to meet Army s aggressive weight targets UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited. 6

7 Light Weight Vehicle Systems M ILEST ON ES FeMnAl Advanced Light Weight Additive Manufacturing Ground Vehicle Loads Friction Stir Welding Operational Metrics Ltwt (M at A ppl & Int) Ltwt C mpn (M at A ppl & Int) A VP T A T o tal A rmy S&T [$ M ] External F unding T o tal Executable [$ M ] LCVSTC Schedule & FundingY15 3 F Y17 F Y18 4 F Y19 5 F Y20 F Y Purpose: All projects developed and executed in accordance with governing Lightweight Combat Vehicle Science & Technology Campaign (LCVSTC). Products: Validated alloy 10% lighter than RHA material Redesigned road arms, spindles, hubs, road wheels, track based on road loads and new material development. Additive Manufacturing Part Repair: Repair light damage such as corrosion, pitting, & wear Remanufacturing: Print replacement part using powder bed system Retool: Utilize 3D sand printing to build molds for casted parts Defined design loads for ground combat vehicles Design guides Generic vehicle design model for design optimization Friction Stir Weld (FSW) process and lap joint designs for joining thick aluminums (7XXX) and Adv. High Strength Steels (AHSS/RHA) Develop operational metrics for weight reduction in support of goal 1.2 of the Army s Lightweight Combat Vehicle Science & Technology Campaign. Payoff: Inform TRADOC, PM/PEO, MCOE on technologies that have impact on vehicle weight. Inform S&T, Acquisition, and Requirements development decisions and investments. Note: The Materials Application & Integration funding is being executed as 6 primary programs all done in support of the Lightweight Combat Vehicle Science & Technology Campaign (LCVSTC). Unclassified Distribution A - FOUO 7

8 AM Opportunities within Army Repair Parts There are opportunities for AM to impact all Army Systems, and at all stages of the lifecycle UNCLASSIFIED: Distribution Statement A. Approved for public release; distribution is unlimited.

9 Enduring Interests: (Gaps) 1. Lightweight advanced materials (e.g., metallic alloys, nano-composites, resin composites, etc.) that meet very high strain rate loading performance 2. Lightweight joining techniques that meet very high strain rate loading performance A. M&S methods/techniques to allow a better understanding and evaluation of weld failure B. M&S methods/characterizing and developing critical design parameters for several classes of adhesive materials C. Dissimilar material joining techniques and M&S to identify the possibilities for military applications a. Material characterization for dissimilar material combinations that are achievable through FSW is needed for proper M&S. b. Microstructure modeling of solid state joining interface 3. Novel light-weighting materials, technologies or methodologies. Holistic vehicle lightweighting techniques a. Example, load-agnostic topology optimization methods 4. Additive Manufacturing (metallic and polymer composites) a. Qualification is the step where the AM machine, material and processes are validated as producing high quality. Need M&S methods to simulate the additive process. b. Certification is the step where the performance of the part is ensured. Unclassified Distribution A - FOUO 9

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