Online-Seminar
Print First Time RightProzess-Simulation in NX für Pulverbett Verfahren
Boris Lauber & Helmut Zeyn
Unrestricted @ Siemens AG 2019
Unrestricted © Siemens AG 2019
Page 2 Siemens PLM Software
Herzlich Willkommen
Helmut
ZeynPortfolio
Development
Additive
Manufacturing
Phone
+49 40 237205-14
Boris
LauberProduct
Management
Simcenter 3D
Additive
Manufacturing
Phone
+49 170 922 4628
Unrestricted © Siemens AG 2019
Page 3 Siemens PLM Software
It’s time to rethinkEVERYTHING
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Page 4 Siemens PLM Software
Innovationen –
Inkrementeller Fortschritt bringt keinen Wettbewerbsvorteil
STATUS QUO
Transformation der Fertigung
Pro
du
kt
Tra
nsfo
rmati
on
Anheben vom Prototypen-Bau zur Industriellen Fertigung
Vo
m k
on
ve
ntio
nelle
n D
esig
n z
um
In
no
va
tive
n P
rod
ukt
Neue Fertigungs-Möglichkeiten
Neue Produkte
• Reduzierung Gewicht, Material
• Scannen Produkt
• Verbesserte Performance
• Innovations-Zyklen verkürzen
• Vermeidung von Werkzeugen
• Vereinfachung Montageprozess
• Lieferkette verkürzen
• Erschwingliche Kleinserien
Neue Geschäftsmodelle
• Individualisierung, Personalisierung
• Null Inventar – Druck auf Bedarf
• Design überall - Drucken überall.
• Innovation beschleunigen
Unrestricted © Siemens AG 2019
Page 5 Siemens PLM Software
Treiber der Implementierung von Additiver Fertigung
Produkt-Komplexität
Konventionelle Produktion
Additive Manufacturing
Ko
ste
n u
nd
Ris
iken
Ko
ste
n
Losgröße
Konventionelle Produktion
Additive Manufacturing (AM) - vor zwei Jahren
AM Heute
AM 5+ Jahre
10 100 1000 10,000
Unrestricted © Siemens AG 2019
Page 6 Siemens PLM Software
Industrialisierung der Additiven Fertigung
Unterstützte Druck-Technologien
EDAG Image
Hybrid additive
Directed energy
deposition
Multi-axis
Fused deposition
modeling
Powder bed fusion
Laser material
fusion
Multi jet fusion
Agent jetting/
inkjet technology
Unrestricted © Siemens AG 2019
Page 7 Siemens PLM Software
Sehr unterschiedliches Knowhow erforderlich
FEM
Topologie-
Optimierung
CAD
FEM
Druck-Vorbereitung
Druck-Simulation
CAM
Print First Time RightSimcenter 3D
Additive Manufacturing
Boris Lauber | Siemens PLM Software
Unrestricted © Siemens AG 2019
Unrestricted © Siemens AG 2019
Page 9 Siemens PLM Software
Challenges in Additive Manufacturing
Laser Powder Bed Fusion (LPBF)
Thermo-mechanical history Recoater collision Local overheating
Support Failure Shrink lines Microstructure & Defects
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Page 10 Siemens PLM Software
Simulation Workflow
Part on Build TraySimulation Supports
Thermal and Mechanical Model
Thermal and Mechanical Results
Predeformation / Compensation
Unrestricted © Siemens AG 2019
Page 11 Siemens PLM Software
Simulation Workflow
Part on Build TraySimulation Supports
• Build Preparation is done on in the
Additive Manufacturing Module of NX
• Simulation is fully integrated into the
AM Workflow
• Position, Build Space, Support
structures are reused for Simulation
Unrestricted © Siemens AG 2019
Page 12 Siemens PLM Software
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Page 13 Siemens PLM Software
Simulation Workflow
Part on Build TraySimulation Supports
Thermal and Mechanical Model
• Separate Meshes for Thermal and
Mechanical Analysis
• Exact Meshing of the Geometry
Unrestricted © Siemens AG 2019
Page 14 Siemens PLM Software
Simcenter 3D Additive Manufacturing
Support homogenization
• Virtual Materials Characterization (VMC) to
homogenize support structure
• Integrated in Simcenter 3D AM
• Possibility to implement homogenized values
manually
Unrestricted © Siemens AG 2019
Page 15 Siemens PLM Software
Simcenter 3D Additive Manufacturing
Meshing and Layer Slicing
Meshing
• Simcenter 3D meshing capabilities is used
to generate high fidelity 3D Meshes
• Detailed meshing allows to consider
geometric details like cooling channels
Slicing
• Powerful Slicing algorithms for building the
layer based models
• Mesh based slicing for thermal analysis
• Solver based slicing allows to realize
1mm super layers for Simulation of the
mechanical distortion
Unrestricted © Siemens AG 2019
Page 16 Siemens PLM Software
Unrestricted © Siemens AG 2019
Page 17 Siemens PLM Software
Simulation Workflow
Part on Build TraySimulation Supports
Thermal and Mechanical Model
Thermal and Mechanical Results
• Full Thermo Mechanical Analysis
• Non-linear Solution
Unrestricted © Siemens AG 2019
Page 18 Siemens PLM Software
Powder Bed Fusion Process Simulation
Simcenter 3D Additive Manufacturing
Goal:
• Enable feedback of SLM process outcome
to Process Engineer and CAD designer
Avoid:
• Too high distortion after manufacturing
• Global & local over-heating
Challenge:
• Producing a part sized around 100mm requires
• ~ 3000 slices
• ~ 10-20 hours of production time
• ~ 5 millions of exposure vectors (5mm each)
• ~ 25 km of “tool path”
• Extreme spread of time- and length scales
Unrestricted © Siemens AG 2019
Page 19 Siemens PLM Software
Simcenter 3D Additive Manufacturing
Macro-scale Mechanical Model
• Simulate thermal shrinkage of whole layers instead of single
tracks
• z-step 500µm-1mm instead of 30-50µm (super-layers w/
effective material parameters)
• effective super-layer parameters must be extracted from meso
scale simulations (or from experiments)
• Whole-part simulation possible
• Unique Siemens Feature: enhanced inherent strain model.
Effective layer Shrinkage Parameter must be a function of
the stiffness
• calibration: Build und measure bridges of different stiffness,
extract effective shrinkage
Unrestricted © Siemens AG 2019
Page 20 Siemens PLM Software
Simcenter 3D Additive Manufacturing
Simulation Architecture
Thermal assessment
Simcenter 3D AM (Macro-Scale)
Calculation of thermo-mechanical distortion
NX CADGeometry
compensation
NX AMBuild
preparation
Local overheating
likelihood
Build
Processor
Standardized
experiment
Unrestricted © Siemens AG 2019
Page 21 Siemens PLM Software
Simcenter 3D Additive Manufacturing
Local overheating
• Local overheating visualized layer by
layer in 2D
• Possibility to have a 3D vision on the
local overheating
• Part of the thermal analysis and short
computational time
Unrestricted © Siemens AG 2019
Page 22 Siemens PLM Software
Simcenter 3D Additive Manufacturing
Stiffness calculation – shrink lines
• Stiffness analysis layer by layer to
identify the areas of potential severe
distortions or shrink defects
• 2D curve with layer stiffness
information
Unrestricted © Siemens AG 2019
Page 23 Siemens PLM Software
Simcenter 3D Additive Manufacturing
VTT Validation case
SimulationOriginal CAD Optical scan (CCAM)
Shrink line locations
correctly predicted
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Page 24 Siemens PLM Software
Unrestricted © Siemens AG 2019
Page 25 Siemens PLM Software
Simulation Workflow
Part on Build TraySimulation Supports
Thermal and Mechanical Model
Thermal and Mechanical Results
Predeformation / Compensation
Unrestricted © Siemens AG 2019
Page 26 Siemens PLM Software
Build process simulation ensures jobs print First-Time-Right
Simulate and predict distortions
Re-parenting supports
Calculated compensated
geometry
Re-Simulate with
compensation
ok
No
Yes
Print first-time-right
Print preparation
Product design
with supports
Virtual detection and
elimination of distortion,
overheating and other defects
with build process
simulation leading
from “try and see”
to First-Time-Right.
Realproduction
Automation
Virtualproduct
Realproduct
Virtualproduction
Unrestricted © Siemens AG 2019
Page 27 Siemens PLM Software
Unrestricted © Siemens AG 2019
Page 28 Siemens PLM Software
Simcenter 3D Additive Manufacturing
Additive Manufacturing Process Simulation
• New Simcenter 3D Product to analyse the 3D printing
process for Powder Bed Fusion.
• Seamlessly integrated with NX Additive Manufacturing
• Open architecture and physics based modeling
• Digital twin of production to simulate:
• Temperature with and without powder
• Probability of overheating
• Distortion before support, after heat treatment as
build
• Compensation workflow
• Prediction of shrink lines
• Recoater interference
• Stiffness calculation
Unrestricted © Siemens AG 2019
Page 29 Siemens PLM Software
Sehr unterschiedliches Knowhow erforderlich
FEM
Topologie-
Optimierung
CAD
FEM
Druck-Vorbereitung
Druck-Simulation
CAM
Unrestricted © Siemens AG 2019
Page 30 Siemens PLM Software
Gemeinsame Entwicklung mit Siemens
Coporate Technology und Anwendern
Boris Lauber
Product Management
Simcenter 3D Additive Manufacturing
Helmut Zeyn
Portfolio Development
Additive Manufacturing