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Design Optimization Process for 3D Printed Designs
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PIDOProcess Integration & Design Optimization
Aerodynamical calculations
Parameters
Mechanicalcalculations
Post‐processingPost‐processing
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Types of Optimization
The available design space
TOPOLOGICAL OPTIMIZATION
The best topology
STRUCTURAL OPTIMIZATION
Structure optimized topologically and structurally
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Topological Optimization
Available design space Early stage of iterative solution
Final stage of iterative solution ( the best topology ) The best topology translated into a real life design
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Topological Optimization
The allowable design space; before topological optimization
The final result shown using iso-surfaces (same density); optimal topology solution
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Frame Lattice Generation• Lightweight structural panels, energy absorption
devices, thermal insulation, porous implants• Infill / Conformal Lattices: PTC AM, ANSYS
SpaceClaim, Materialise Magics, Simpleware, Paramount Industries, NetFabb / Autodesk Within
• Mature Topology Optimization codes use element mesh to generate lattice structures
• We need smart lattice generation coupled to Topology optimization– Lattice element size based on the density field– Node repositioning / rezoning base on density field– Smooth transition between solid & lattice
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Frame Lattice Generation
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Smooth transition for Frame Lattices
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Infill with Minimal Surfaces
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New 2 ½ D Lattice feature in CREO 4
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New 2 ½ D Lattice feature in CREO 4
Gear
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Solid 2 ½ D Lattice feature for solid meshing and 3D printingFull Geometry Option
cube2
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Simplified 2 ½ D Lattice feature for shell meshingSimplified Geometry Option
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Solid 3D Lattice feature for solid meshing and 3D printingFull Geometry Option
cube2
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Solid 3D Lattice feature for solid meshing and 3D printingFull Geometry Option
thermal2
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How do I Design today for Additive Manufacturing (DfAM)?
Creo 4 Lattice Feature
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Step 1: Homogenization – Cell size & configuration • Find the effective
property of the cellular structure using Creo Simulate
• Average of physical & mechanical properties of cell (ρ,ν,E)
• You could estimate without regard to the cellular geometry itself with volumetric scaling
• You could use experimental data by power law curve fitting Eeff=c*E*(Vcell/V)^n
• Homogenized material properties can be used in topology optimization
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Step 1: Homogenization using CREO Simulate
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Step 2: Establish Design Space and Performance Requirements (Safety Factors, displacement limits, ω, etc.)
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• Output of Topology Optimization is an organic shape .stl file.
• There is a need to create geometries out of our topology optimization results
• Sub‐divisional surface modeling such as CREO free style is a practical solution
• The challenge is to identify all the segments / subdivisions and the potential unions of the free style primitives
Step 3: Setup and run Topology Optimization with all Performance Requirements
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Step 3: Use CREO FreeStyle Primitives to “Reconstruct” the Topology Optimization suggested geometry
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Step 4: Use Lattice feature to generate the lattice structureUse simplified option for beam generation in Creo Simulate
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Review Simplified Lattice Structure Representation
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Step 5: Use Creo Simulate to specify loads, boundary conditions and generate mesh with beam and solid elements
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Review the Simplified Beam Element Representation of the Lattice Structure
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Review the displacement Distributions and Validate performance Requirements
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Review the Simplified Beam Element Representation Results of the Lattice Structure
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Redefine Lattice Feature with the “Full Geometry” Option
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Lattice Feature with the “Full Geometry” Option
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BMX can also be used to Optimize Designs where closed form solution is available
• Generate Analysis features of relevant information (i.e. Areas, Moment of Inertia, etc.)
• Create relation or Mathcad Prime features to compute performance attributes (safety margins, stress, deflections, buckling loads, natural frequencies, etc.)
• Perform sensitivity analysis to evaluate the feasibility of the design and establish design limits of design variables
• Perform Design Optimization to select lattice structures’ dimensions
• If contradicting performance requirements are essential use multi‐objective design study with pareto optimization
• If Design For Six Sigma (DFSS) requirements are essential use Statistical Design Studies to generate a robust Design
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Any parameter that defines the lattice can be used as design variablein BMX, Creo Simulate or Mechanism Dynamics Optimization
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Lattice Structure inside Base with a Parabolic Beam
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Lattice Structure with a Straight & Parabolic Beams
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Geometry / FEM• CAD Part with PMI• Lattice Structure• Support Structure• FEM Mesh• Physics definitions
3D Printer• Control Software• Printability Checks• Layer thickness• Disposition path• Build orientation• Print Preview• …
Material Selection• Alloy composition• Powder diameter• Powder compaction• Service active trace elements• …
Multi Physics Simulation for Characterization
of Additive Manufacturing
Materials
Material Performance Field• Modulus of elasticity Ex(x,y,z)• Poisson’s ratio• Coefficient of thermal expansion• Density• Yield strength• Ultimate strength• Fatigue strength• Residual stress distribution• Distortion of the part• Damping• Thermal conductivity• etc.
Processes Settings • Laser power• Pulse rate• Spot size• Velocity• Spacing
Fundamental Challenge Characterization of Additive Manufacturing Materials
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Short Course by AES on:Design Optimization Process for 3D Printed Designs
• Is your organization ready to unleash the full potential of Additive Manufacturing?
• A three day course on Design Optimization Process for 3D Printed Designs
• Learn how to:– Create in CREO parametric 2 ½ D and 3D Lattice Features– Learn how to size and generate Lattice Structures– Optimize Lattice Structures using Behavioral Modeling– Use topology optimization to find the best distribution of material
for stiffness or compliance with homogenization techniques– How to reconstruct the CAD geometry from the optimization
results (Nurbification)– Design for additive manufacturing and practice the validation and
verification steps required for Aerospace & Defense applications– Use topology optimization for light weight heat exchangers– Synthesize Metamaterials using Topology Optimization & Lattices