Additive Manufacturing Workshop for Aerospace Suppliers · Generative Additive Process with Physic...
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Transcript of Additive Manufacturing Workshop for Aerospace Suppliers · Generative Additive Process with Physic...
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Additive Manufacturing Workshop for Aerospace
Suppliers
Abelardo GarzaSenior Technical Sales Consultant, NAM
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Additive ManufacturingBio-inspired Generative Design
From Concepts to Functional partsOptimized for Material, Process and within Allowables
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5 Dassault Systemès Additive Manufacturing Solutions
Science-based Generative Design
Digital Manufacturing Solutions
Physics-based Process Simulation & Optimization
Outline
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Shaping the Future of Additive Manufacturing
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Function based GenerativeDesign3 In-silico material engineering2
Process definition &Production planning4
Global production system5
3DExperience Marketplace for Additive Manufacturing1
3DS Additive Manufacturing Solution
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3DExperience Marketplace for Additive Manufacturing1
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In-silico material engineering2
Grain segregation of a Titanium Alloy Melting & Thermal conductivity of a Nickel AlloyVIRTUAL Material Lab• Certify existing materials for AM• Engineer New material for AM• Control the micro-structure of the processed material
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Functional Generative Design3
Innovative Designs• Organic shapes• Function integration • Assembly Optimization• Performance improvement• Weight reduction
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Process Definition and Production Planning4
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Global Production System5
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Function based GenerativeDesign3 In-silico material engineering2
Process definition &Production planning4
Global production system5
3DExperience Marketplace for Additive Manufacturing1
3DS Additive Manufacturing Solution
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Model-based Approach – Breaking Silos
Solid Modeling Finite Element Topology
Optimization
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Science-basedFunctional Generative Design
for Additive Manufacturing
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Science-based Functional Generative Design
Unifying Modeling, Simulation and Optimization in a single environment
• Efficient Product Engineering, removing bottlenecks thatusually make it cost-prohibitive to explore optimized parts.
• Intuitive workflow for Designers , with non-expert solutions
• Automatic generation of function-driven conceptual shapes and detailed organic shapes
• Seamless Collaboration with Designers, Simulation and Manufacturing Engineers.
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Functional Generative Design Workflow1. Functional Specifications
2. Concepts Trade Off
3. Generative Shape Modeling
Manufacturing Process & Simulation
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Define Load Case & Boundary Conditions
Create Design Space& Mechanical Interfaces
Define Targets& Constraints
Variants Review & Concept(s) Selection
Design Review
Detailed refinement
Detailed Refinement
Structural Validation
Structural Validation
Detail Design(ALM)
Design Concept Generation
Structural Pre-Validation
Variants Creation
Explore Concept
Detail Design (Milling)
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Generative Concept Design Key Takeaways
Multidisciplinary Intuitive Automated Collaborative
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Function based GenerativeDesign3 In-silico material engineering2
Process definition &Production planning4
Global production system5
3DExperience Marketplace for Additive Manufacturing1
3DS Additive Manufacturing Solution
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Ceramics
Metals
Plastics
OthersSteel, bronze, gold, silver, titanium… Composites, Food, biocells,
bioplastics…
Nylon, rubber like, resin, photopolymers…
Glass, Quartz, silica
A.Materials
B.Processes to manufacture the materials
Free your mind for innovate design …
…..with materials & processes that will make them feasibleAdditive Manufacturing | Opens new design possibilities
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Additive Manufacturing | Manufacturing Process
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Process Planning - Define the production steps to dispatch
across the manufacturing assets- Optimization of the production time and
resources utilization (station …Machine)
Process Optimization- Predictive Analytics to:
- Reduce Part Stress and Distortion- Minimize Print Time
- Increase dimensional accuracy- Prescriptive Analytics to:
- Optimize manufacturing constraints
Generative Additive Process with Physic-based simulation- Select a predefined “Process Template” - Generate the position & orientation of the part on the machine , supports
and laser path according to Material (powder properties) Machine capability and Design Intent/Characteristics
- Progressive material addition analysis- Thermal residual stresses / Part Distortions- Generate the outputs for Fabrication (3MF, Machine Code, Models for
other operations …)
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Digital Manufacturing Key Takeaways
Process Preparation
Support Structure
Generation
Slicing & Scan Path
Generation
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Additive Manufacturing: Reliability Concerns
Thermal effects produce residual stresses that can lead to cracking or failure during manufacturing or
product life
Manufactured material properties differ from raw
material properties (function of process)
Accumulated stresses lead to distortions that can
render the part unusable
Material Properties Cracking and Failure Distortion
Attribution: By Benrobuck (Own work)License: CC BY-SA 3.0
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“As-Designed” Part
The Gap between “As-Designed” and “As-Manufactured”
Designed geometry without stresses or distortions
Standard material property assumptions
Process Gap
• Materials• Deposition Path• Build Definition• Heat Input
• Residual Stresses• Distortions• Altered Properties
“As-Manufactured” Part
• Residual stresses built up from thermal process
• Deformations causing tolerance issues
• Material properties are a function of manufacturing process
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Polymer Extrusion Metal Printing Direct Energy DepositionWelding
Heating Inputs Time Fidelity Part Fidelity Material Evolution
Cooling Boundaries
An all-purpose Process Simulation Framework
SLS DEDFDM
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5 Path, Process, and Build Information
Evolving Free Surfaces
Time Fidelity: localized heating to full part
solutions
Material Evolution: phase change/material
lay-up
Seamless inclusion of support structures
Simulation based prediction of part
distortions
From Functional Designs to Reliable Parts
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Physics-based Additive Manufacturing SimulationPrint Temperature Residual Stresses
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Flexible Process Simulation Capabilities
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Process Parameter Optimization (Print Speed) Automate the Process Modeling methodology Print speed is one of key process parameters-Reduce print time with minimal residual stress and distortion.
Temp
eratu
reSt
ress
Print Time: 15 hr Print Time: 5 hr Print Time: 2hr Print Time: 1.5hr
IDEAL SOLUTION
Higher Stresses And Distortions
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Process Parameter Optimization (Support Structures)
Support Design 2Vol: 1.25e-5 m3
Support Design 1Vol:4.2e-5 m3
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Temperature distribution using Process Simulations
Support Design 2Support Design 1
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Post-Processing: Support Removal and SpringbackSimulation with Supports Springback after Support Removal
Springback in Context of Support Locations
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Direct Energy Deposition| Ti-6Al-4V
** Denlinger, E. R., Heigel, J. C., Michaleris, P., & Palmer, T. A. (2015). Journal of Materials Processing Technology, 215, 123-131.
Mechanical Deflections: Abaqus Static Analysis correlation with experiments**
Dashed: Measured
Solid: Simulated
Dashed: Measured
Solid: Simulated
Thermal History: Abaqus Thermal Analysis correlation with experiments**
Direct Energy Deposition| Ti-6Al-4V
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Physics-based Additive Manufacturing Simulation Key Takeaways
Physics-based
Accurate modeling
Flexible framework
Process Optimization
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Additive Manufacturing Solutions Key Takeaways
Physics-based simulation for AM
Digital Manufacturing Process Preparation
Generative Design
3DExperience Platform
