Closing the gap in the design to additive manufacturing chain by numerical tools

Transcription

1 Closing the gap in the design to additive manufacturing chain by numerical tools European Altair Technology Conference Frankenthal Nils Keller Additive Works GmbH

2 Additive Works 2 Additive Works GmbH - Spin-off company of the Universitity of Bremen, Airbus Endowed Chair for Integrative Simulation and Engineering of Materials and Processes (ISEMP), funded by EXIST Forschungstransfer - Founded December Vision: AM (LBM) as One-Click Process - Software product Amphyon since April Currently 6 employees - Customers from aerospace, medical engineering, tool construction, automotive, research and development - Collaborations with machine vendors: first fully integrated simulation solution in process software 3DXpert

3 Amphyon Amphyon Simulation and process software for AM Software suite Amphyon with various modules for pre-processing: - Easy to use GUI - Fast calculation times - No FEM knowledge needed - Focus on process, not simulation - Non-FEM modules

4 Laser beam melting From design space to physically parts Idea: Create function-optimized designs and use the design freedom of additive manufacturing technology Topology optimization Design Space Additive Manufacturing Do we really have that freedom of design or is still a manufacturing driven design needed?

5 Laser beam melting Laser Beam Melting Technology of the 21th century 3D Model LBM-Process Part Sources: Fraunhofer ILT, APWorks, Airbus

6 Laser beam melting Laser Beam Melting Technology of the 21th century 3D Model LBM-Process Part??? Built shape Distortion Desired shape Cracking Surface defects Design-, orientation- and support structure dependent result Unreliable process in terms of the idea

7 Laser beam melting Design constraints by manufacturing process? Easy example: definition of minimum wall thickness: Build-up direction 1mm Strong coupling between geometry and build-up direction Design Build-up direction Needed: 2mm Orientation

8 Laser beam melting Design constraints by manufacturing process? Easy example: definition of minimum wall thickness: Wall or plate? Build-up direction Support structure needed? - removal - material usage - process time - post-processing How to integrate all these factors into the design stage (topology optimization)? Possibleorientation should be considered while construction stage!

9 Examination 9 Solution: Amphyon Examiner Consideration of all (possible) orientations: Accessibility Build time Support volume Post-processing effort Distortion tendencies + Functional faces Build chamber

10 Examination 10 Analysis of all build-up directions Ideal orientation + Assessment customizable criterias

11 Topology optimization Usage in topology optimization Example for usage of the Amphyon Examiner module together with topology optimization Topology Optimization Orientation + Assessment Examination/Orientation Design Support structure and distortion?

12 Process simulation 12 AM process simulation Full scale Simulation MLE Approach (inherent strains in AM) Problem: kilometers of weld paths Layerwise thermo-mechanical simulation Calibration of heat source Calculation of forces Reduction to mechanical problem Problem: Inaccurate and instable Calculation time << Process time

13 Validation 13 Validation of the MLE simulation method Simulated and measured deformation at the surface compared to the desired shape 1 Deviation [mm] Calculated geometrical deviation (Projection on CAD) Measured geometrical deviation (Cutting after process) -1

14 Distortion compensation 14 Distortion compensation by pre-deformation Prediction and Compensation of residual deformations Process distortions (on plate) Final distortion (cutted after process) Calculation time: ~ 10min

15 Support optimization 15 Support optimization Workflow for simulation based support optimization and generation: STL-import Reduced material use Increased process stability Decreased development time Easy workflow Reduced post-processing Optimized support structure Design space Preferences & Process-info Fast Optimization Generate or Load STL Calculation time: ~ 1h for 100k elements

16 Support optimization 16 Support creation Benefits: - No manual choice of support structures needed - No geomtrical limitation - Apllication specific optimization criterias

17 Topology optimization 17 Future approach? Topology Optimization Process Simulation Examination/Orientation Compensated design + Orientation + Support structure ready to print

18 Thank you for your attention! 18 Contact Nils Keller, PhD CEO Additive Works GmbH Leher Heerstr. 173B Bremen Tel.: +49-(0) Office Additive Works GmbH BITZ Fahrenheitstr Bremen Tel.: +49-(0) info@additive.works