Nouveautés ANSYS pour le calcul structurel et l impression 3D. CADFEM 2017 ANSYS Additive Manufacturing

Transcription

1 Titelmasterformat Journée Technologique durch AddiPole Klicken bearbeiten Nouveautés ANSYS pour le calcul structurel et l impression 3D

2 Titelmasterformat Structural design with durch ANSYS Klicken bearbeiten

3 Additive manufacturing Functionality Load cases

4 Your Cyber Physical System = Digital & Hardware Twins Modules Integration High rate throughput Controls, logics, delays Robust Design Optimization RDO Stochastic variations Tolerances Prescriptive analytics product Metamodels, MOR, Co-simulation, Strong Matrix coupling

5 ANSYS Mechanical ANSYS Mechanical Solutions Linear and non-linear structural mechanics Contact analysis with and without friction All kinds of non-linear material properties Large deflection and stability analysis Bolt pretension analysis Thermal stress analysis Multiple load steps Limit load analysis Equivalent v. Mises stress Equivalent plastic strain Large deflection analysis with non-linear contact and plastic deformation

6 Element Technology ANSYS Mechanical Solutions Complete and consistent suite of structural elements Beam Shell, SolidShell Solid Contact Spring, Damper ANSYS Workbench automatically assigns appropriate element type Shell-model MPC connection Solid-model Hybrid Solid-Shell model

7 Contact Analysis ANSYS Mechanical Solutions Contact pressure Deformation

8 Material Modeling ANSYS Mechanical Solutions Material models for all kinds of material (> 60 models) Metal, Rubber, Plastic Composites Time dependent (Creep) Temperature dependent Deformation Plastic Strain Element Technology Shape Memory Alloys Metal Inelasticity Rubber Elasticity Drucker-Prager Plasticity Rate-Independent Behavior Rate-dependent Behavior Anisotropic Behavior Rate-Independent Behavior Rate-dependent Behavior

9 ANSYS Mechanical Solutions Analysis of Thin Bodies Shell Meshing Shell meshing requires the extraction of a mid-surface model from an existing 3D-CAD geometry Mid-surfacing may need considerable time in case of large complex geometries The shell thickness is automatically extracted from original geometry 3D CAD Geometry Mid-surface model Shell Mesh

10 Bolt Pretension Analysis Bolt pretension analysis First step: pretension calculation Second step: load analysis Stepped bolt pretension ANSYS Mechanical Solutions Contact Pressure Load step definition and convergence of non-linear contact analysis

11 ANSYS Mechanical Solutions Structural Dynamics Harmonic Analysis Harmonic analysis yields displacement and stresses as a function of frequency A harmonically varying forces or displacements can be applied Includes pre-stress effects and damping Harmonic Response 4. Eigenfrequency 3. Eigenfrequency

12 Structure dynamics (2D,3D): several components (compliance, integrity, feeling) source: CADFEM

13 Rigid/Flexible Dynamics A dynamic analysis in time domain is required if non-linear effects have to be accounted for Large deformation Non-linear contact Non-linear material behavior Fast rigid body transient analysis Combination of rigid and flexible bodies Flexible body analysis numerically considerably more expansive ANSYS Mechanical Solutions

14 Explicit Dynamics Easy access to explicit structural mechanics for ANSYS users Simulation of large nonlinear and transient dynamic problems with LS-DYNA or Autodyn Drop test Manufacturing, Forming Load Limit Analysis including material failure ANSYS Mechanical Solutions

15 Fatigue - Life ANSYS Mechanical Solutions

16 ANSYS Thermal Static and transient analysis Radiation Phase change Thermal contact analysis Thermal stress analysis Thermal Analysis of an Exhaust System 271 parts 554 contact pairs Thermal Analysis of an Engine Block Thermal Contact Analysis

17 For non experts: Discovery live

18 Example Optimization of a pitch arm of a helicopter rotor head

19 DEMO: Pitch Arm with Discovery Live

20 Titelmasterformat Topology Optimization durch Klicken bearbeiten

21 Optimal Design via Topology Optimization Design space Loadcases Topologyoptimization.stl Base Model Smoothing PRINT Validation Meshing CAD reverse engineering Source: CADFEM Medical

22 Lattice Structures (Beta)

23 Lattice Structures (Beta)

24 Lattice Structures (Beta)

25 Lattice Structures (Beta)

26 Example : Pitch Arm

27 DEMO: Pitch Arm Topo Opti

28 STL Preparation for Additive Manufacturing Coarse demo Fine

29 ANSYS SpaceClaim for Additive Manufacturing Dedicated tools to: Clean/repair models before printing Holes, self-intersections, connections, duplicates, sharps Prepare models Boolean, split, shell, infill, thicken, smooth Analyzing printability: Thickness, overhangs Edit not just repair! Unique hybrid modeling (CAD +facets in one environment) Sketch new geometry to add/remove/improve facets

30 ANSYS SpaceClaim for Additive Manufacturing New Skin Surface tool for interactive surface fitting to faceted models. 5 seconds

31 ANSYS SpaceClaim For Reverse Engineering Dedicated tools to: Fit curves to mesh cross-sections Fit basic shapes: Planes, cylinders, spheres Fit surfaces to selected regions Reference Modeling Pull Up To mesh regions: Fillets, extrusions, revolves Select mesh regions by similar curvature Select mesh edges (directional, open, etc) Sketch on mesh

32 Geometry conversion Detail (Redesigning)

33 Validation System Stress Original,

34 Validation System Stress Optimized,

35 Validation System Comparison Mass [%] Deformation [%] Stress [%] Original Optimized

36 Titelmasterformat ANSYS Additive Print durch Klicken bearbeiten Fast Process Simulation for Print Optimization

37 Fast Process Simulation For the Process Engineer and Machine Operator: ANSYS Additive Print Optimize Process: Find good print direction Find good support strategy Find good print parameters Goal: Avoid failed prints

38 ANSYS Additive Print Software GUI

39 Application example: Distortion compensation Original Geometry Compensated Geometry

40 Blade Crash Prediction As the part is being build, the recoater blade may run into the part damaging the part, and potentially the machine

41 Automatic support structures Automatically generated physics based support structures Residual stresses after support removal

42 3 levels of fidelity

43 DEMO: PRINT

44 Titelmasterformat ANSYS Additive Suite durch Klicken bearbeiten Workbench Additive Capabilities / Mechanical Additive Process Simulation (MAPS) Additive Science for experts

45 Design for AM with ANSYS

46 Features of ANSYS AM Suite Options for Simplified Thermal Analysis AND Detailed Thermal Analysis Topology / Lattice Optimization Distortion / Residual Stress / Failure Prediction Automatically Compensate Geometry for Distortion Four Strain Mode Options STL File Repair / Manipulation Location-Specific Microstructure Output Geometry-based Support Generation Physics-based Support Generation Porosity Predictions Simulate using Machine Scan-Vectors Thermal Sensor predictions

47 DEMO: Pitch Arm AM

48 Print direction ANSYS Mechanical Additive Process Simulation Individual support structures, print orientation, process parameters

49 ANSYS Mechanical Additive Process Simulation Temperature Displacement Stress

50 ANSYS Mechanical Additive Process Simulation Mesh Temperature Displacement

51 ANSYS Mechanical Additive Process Simulation Stresses Displacement Stresses

52 ANSYS Mechanical Additive Process Simulation Detect and generate support for an overhang angle of 44

53 ANSYS Mechanical Additive Process Simulation Manual support structure changes: Maybe you want to avoid that support is placed on top of the build part Own support structure Getting rid of very small or unreasonable support structures In doing so, pay attention to sharp angles without fillets that are not identified by the overhang angle search function

54 ANSYS Mechanical Additive Process Simulation Detect and generate support for an overhang angle of 45 => yields a more realistic support structure:

55 Lumped Layer Approach Global model heat source Applying the power by using temperature T Reality: Power (Time) Temperature (Time) 1 layer: Q, Δt E = Q Δt 100 layers: Q, Δt E = 100 Q Δt Power Zeit Temperature Zeit Simulation (ANSYS): Power (Time) Temperature (Time) Power Temperature 1 layer: ΔT E = ΔT V c ρ 2 layers: ΔT E = 2 ΔT V c ρ Disadvantage: not conforming to time Simulation-time This way is used in ANSYS Simulation-time

56 How to adapt this solution to special simulation requirements amtype,pbf This specifies the additive manufacturing process type. In this case it is Powder Bed Fusion. It is also possible to specify Direct Energy Deposition (DED) Lower Base Plate Apply Powder Layer Exposure Powder Bed Fusion

57 ADDITIVE SUITE Roadmap January 2018 New Features 19 (March 2018) New Features 19.1 (May 2018) New Features 19.2 (Sept 2018) New Features 20.X (2019) New Features ADDITIVE PRINT Stand Alone Product, bundled with SpaceClaim Included as a Stand-Alone Product DESKTOP Availability ANSYS Viewer integration HPC for Local Parallelization Import Externally Generated Supports ANSYS Workbench (beta) Integration (Optional) Advanced Support Generation Build Platform Optimization Heat Treatment HPC Distributed Parallelization Full Mechanical Enterprise Integration Lattice-based Support Structure Optimization WORKBENCH ADDITIVE CAPABILITIES Mechanical Process Simulation (beta) SpaceClaim Lattice Construction & faceted data handling Topological Optimization Full Product Release Lattice Optimization Support Generation Heat Treatment (beta) Lattice-based Support Structure Optimization (beta) Heat Treatment Lattice-based Support Structure Optimization ADDITIVE SCIENCE CLOUD Availability (Beta) Cloud (w/ansys Viewer) and Desktop (beta) Full Release of DESKTOP Stand-Alone Microstructure Predictions Workbench Integration (beta) Full Mechanical Enterprise Integration Microstructure Based Property Predictions Machine Process Parameter Development Toolkit Requires Mechanical Enterprise License

58 Take Home: ANSYS AM Process Topology Optimization Design with Physics insights (Discovery Live) 1? 44 AM Process Simulation STL Cleanup QS Check