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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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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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

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

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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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

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.

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

Additive Manufacturing Workshop for Aerospace Suppliers · Generative Additive Process with Physic...

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