cae and rapid prototype
Post on 03-Jan-2022
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The University of Michigan
Computational Mechanics Laboratory
CAE and Rapid Prototype
1. Integrated Design Approach
2. Future CAE : Image Based
3. Rapid Prototype
4. Layered Manufacturing
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The University of Michigan
Computational Mechanics Laboratory
Toward Integration
for
manufacturing
Production Engineering
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The University of Michigan
Computational Mechanics Laboratory
Integrated Design Approach
• Geometric Modeling– CAD (non-existing) and CT Scanning (existing)
• Image Based CAE– Image Based Analysis Model Development
– FE Analysis / VOXELCON
– Redesign and Design Optimization / OPTISHAPE
• Rapid Prototype with Common Database
• Layered Manufacturing
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The University of Michigan
Computational Mechanics Laboratory
Common Database
• We have common database : compressedimage data with jpeg/gif format that can berapidly converted to STL and SLC fileswhich are common in rapid prototype andlayered manufacturing
• 500 slices data can be about 7 MB
• CAD IGES or STEP format is not sufficientto construct an integrated system
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The University of Michigan
Computational Mechanics Laboratory
Image Based CAE- a new concept -
for
an integrated system
of
Production Engineering
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The University of Michigan
Computational Mechanics Laboratory
Started From OPTISHAPE
Optimal topology/shape is
represented by pixel/voxel on/off
condition (image)
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The University of Michigan
Computational Mechanics Laboratory
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The University of Michigan
Computational Mechanics Laboratory
Why Not To Use This !
Apply CT Scanning Scanned3D Image
Voxel Mesh for FEA
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The University of Michigan
Computational Mechanics Laboratory
Scanning / Example
l 1 Week with $ 2,800
resolution : 0.2 ~ 0.5 mm
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The University of Michigan
Computational Mechanics Laboratory
CT Slices of the Caliper
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The University of Michigan
Computational Mechanics Laboratory
3D Surface Rendering
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The University of Michigan
Computational Mechanics Laboratory
Stress AnalysisMesh From CT Scan150,000 3-D Elements
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The University of Michigan
Computational Mechanics Laboratory
Design Optimization9% Weight Reduction
OPTISHAPE
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The University of Michigan
Computational Mechanics Laboratory
Comparison by Sections
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The University of Michigan
Computational Mechanics Laboratory
Rendering of Designed One
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The University of Michigan
Computational Mechanics Laboratory
Advantage of IBCAE
l Scanning ~ At Most 1 Week
l FE Meshing ~ A Few Minutes
l FE Analysis ~ 1 to 2 Days
l Total 10 Days
l Standard FEA 3 Months or more
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The University of Michigan
Computational Mechanics Laboratory
Why Image Baed ?
OPTISHAPE
+
Rapid Prototype Technology
Solid Free Form Fabrication
Short Turn Around Time
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The University of Michigan
Computational Mechanics Laboratory
Common Database for CAD
• VOXELCON & OPTISHAPE generate STLfiles of solid models and optimized layoutof structures
• STL files are used in Rapid Prototypeequipment such as SL machines
• From STL files SLC files as well as WireFrame models are generated
CAD Linked Common Database
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The University of Michigan
Computational Mechanics Laboratory
SFF is a Key Technology
FREE FORMFABRICATION
DIRECTENGINEERING
RAPIDTOOLING
for Advanced Engineering and Fabrication Process
Design ConceptProduct & Process DesignMfg. & Product CAEPrototypeFixture Design
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The University of Michigan
Computational Mechanics Laboratory
Free Form Fabrication(SFF)
SFF is an array of different technologiesfor the purpose of creating physical objects directly from three dimensionalsurfaced or solid geometric data byutilizing very thin slices of the geometricdata to create the model
--- Mr. Peter R. Sferro, Ford Motor
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The University of Michigan
Computational Mechanics Laboratory
SFF Benefits & Growth
l According to Mr. Sferro, Ford Motor,only300 parts are FFFed in 1988, but more than15,000 parts in 1994
l Savings– Cost 50 ~ 75%
– Timing 70 ~ 95%
l Quality : Optimized Design
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The University of Michigan
Computational Mechanics Laboratory
Typical SFF Technologies 1
l Sintering
l Lamination– KIRA, HELISYS, FORD, CAD/LAM
l Jet Droplets– MIT, SANDERS, BPM, SOLIDGEN
l Photo Polymer– Stereo-Lithography, Cubital, EOS, Sony
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The University of Michigan
Computational Mechanics Laboratory
Typical SFF Technologies 2
l Extrusion– IBM, STRATASYS
l Welding– Rocketdyne, Sarasota, Nottingham
l Plasma Spray– MD, Stanford
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The University of Michigan
Computational Mechanics Laboratory
Stratasys
About $65,000for this equipment
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The University of Michigan
Computational Mechanics Laboratory
Examples by Stratasys
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The University of Michigan
Computational Mechanics Laboratory
Design To Rapid Prototype
l Image Processing from Voxel Data in theHomogenization Design
– remove of point contact
– manufacturability constraints (curvature)
– creation of a SLC/STL file for SFF
l CAD data generation for SFF
l Rapid Prototype by SFF(Solid Free FormFabrication) Machines
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The University of Michigan
Computational Mechanics Laboratory
Isotropic Material Design
nPoisson’s ratio -0.5
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The University of Michigan
Computational Mechanics Laboratory
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The University of Michigan
Computational Mechanics Laboratory
Rapid Prototype
Prashant Kulkarni
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The University of Michigan
Computational Mechanics Laboratory
Layer-by-Layer
l Emerging manufacturing technology isbased on layer-by-layer, point-by-pointformation of a shape ( geometry )
– Reverse way of formation of geometry
– Sculpture is taking out unnecessary portion, but
– These methods is building up a shape point-by-point, and layer-by-layer
– Truely digital formation of a shape
l Why not paying more attention to this !
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The University of Michigan
Computational Mechanics Laboratory
Layered Manufacturing
l Rapid Prototype– Stereo-Lithgraphy
– Fusion Deposition
– 3D Printing
l LayeredManufacturing
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The University of Michigan
Computational Mechanics Laboratory
Typical Layerd ManufacturingProcesses
Stereolithography Selective Laser Sintering
Fused Deposition Modeling
Foam foundation
Roll of raw material
rollersheating chamber
nozzlepowder bed
powder storage
CO laser2
roller
mirrorvat of liquid polymerElevator
table
mirror
He-Cd Laser
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The University of Michigan
Computational Mechanics Laboratory
A Comparison
SLA – StereolithographySGC – Solid Ground CuringSLS – Selective Laser Sintering3DP – Three Dimensional Printing
FDM – Fused Deposition ModelingLOM – Laminated Object Manufacturing
SMM – Sanders Model MakerSDM – Shape Deposition Modeling
build matl.liquid powder solid
wax
plastic
ceramic
paper
metal
FDM SMM
3DPSLA
LOM
SGC SLS FDM SMM
SLA 3DP SLS
SDM
_
_
_
_
SLS
_ 3DP SLS
,
, , ,
,
,
State of
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The University of Michigan
Computational Mechanics Laboratory
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The University of Michigan
Computational Mechanics Laboratory
Now there is possibility to makein real sense integration
For
Production Engineering
Based on
the Concept of OPTISHAPE
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The University of Michigan
Computational Mechanics Laboratory
We are heading to
Development of an integrated systemfor Computer Aided Production
Engineering ?
CAPE
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The University of Michigan
Computational Mechanics Laboratory
OPTISHAPE
Present & Near Future
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The University of Michigan
Computational Mechanics Laboratory
OPTISHAPE QUINT
TOPOLOGY Michigan Kikuchi/Diaz
SHAPEToyohashi Azekami
SIZINGNASA Ames Dr. Miura
FLEXIBLEMULTI-BODIES Michigan Kikuchi/Nishiwaki
MSC/PATRANSDRAC I-DEAS
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The University of Michigan
Computational Mechanics Laboratory
Other Activity
• ALTAIR Computing– OPTISTRUCT X GENESYS
• Vanderplat Associate– GENESYS X HYPERMESH/OPTISTRUCT
• MSC Europe– MSC/TOPOLOGY (Just Static)
• ANSYS TOPOLOGY (Just Static)
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