generating the digital thread for backlogged parts that ... · generating the digital thread for...
TRANSCRIPT
![Page 1: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/1.jpg)
Generating the Digital Thread for Backlogged Parts that Lack TDP
Dr. Andreas VlahinosChief Technical Officer
Advanced Engineering SolutionsCastle Rock, CO, [email protected]
James D. MetzgerSenior Consultant, CGI Federal
in support of U.S. Army AviationHuntsville, AL, USA
Model-Based Enterprise Summit 2019 NIST, Gaithersburg, MD
April 1 - 4 2019
![Page 2: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/2.jpg)
Generating the Digital Thread for Backlogged Parts that Lack TDP
• Sometimes aerospace manufactures of the defense industry go out of business or the parts are so old there are no TDP or performance requirements are not available
• This presentation will provide a methodology for a rapid response to organizations that need to:– Generate a Technical Data Package (TDP)– Introduce the part into the Digital Thread– Improve part’s performance– Reduce part’s weight– Explore Alternative Manufacturing Options– Manufacture fast backlogged spare parts– Reduce part’s time to manufacturing
![Page 3: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/3.jpg)
Scanned Data for Tail Wheel YokeSince there is no access to Computer Aided Design (CAD) model data for these components, a reverse engineering (RE) technique need to be employed to generate the geometry of the Baseline Geometry in a parametric feature based CAD format.
![Page 4: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/4.jpg)
Scanned Data Tail Wheel Yoke
![Page 5: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/5.jpg)
Scanned Data for Tail Wheel Yoke
![Page 6: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/6.jpg)
New Parametric CAD model & Scanned data
![Page 7: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/7.jpg)
Section New Parametric CAD model & Scanned data
![Page 8: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/8.jpg)
High Quality CAD Model (TDP)If complex surfaces are present a Sub-Divisional surface modeling technique (Sub-D) is deployed
![Page 9: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/9.jpg)
High Quality CAD Model with PMI (TDP)
![Page 10: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/10.jpg)
Supports and Loading ConditionsThe static load levels and the natural frequency limits can be determined by assuming that the existing design meets all structural and dynamic performance requirements.
![Page 11: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/11.jpg)
Displacement Distribution
![Page 12: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/12.jpg)
Stress Distribution
![Page 13: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/13.jpg)
Stress Distribution
![Page 14: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/14.jpg)
Design Domain and Keep out RegionsEnhancing this Reverse Engineering process with Generative Design and Lattice Structure generation techniques presents an opportunity to not only reproduce the part but improve its performance, reduce its weight and reduce its time to manufacturing
![Page 15: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/15.jpg)
60 % of Original Weight
![Page 16: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/16.jpg)
50 % of Original Weight
![Page 17: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/17.jpg)
50 % of Original Weight
![Page 18: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/18.jpg)
50 % of Original Weight
![Page 19: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/19.jpg)
CAD Model of Optimized GeometrySub Divisional Surface Model
![Page 20: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/20.jpg)
CAD Model of Optimized GeometrySub Divisional Surface Model
![Page 21: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/21.jpg)
• Since the additive manufacturing (AM) industry continues to grow with new machines, faster processes and a large selection of materials there is a great opportunity to redesign these parts using Lattice Structures and Generative Design Techniques.
• Lattice structures such as Gyroid minimal surfaces are very effective for light weighting, energy absorption, dynamic damping, ballistic protection, etc.
• The combination of Sub-Divisional surface modeling, Topology Optimization, manufacturing constraints and Lattice Structure generation tools enable us to generate optimum designs.
Reduce part’s fabrication time with Additive Layer manufacturing
![Page 22: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/22.jpg)
Optimized Geometry Design Option 2 for AM
Organic Geometry
![Page 23: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/23.jpg)
Design Option 2 Fully Stressed Geometry
![Page 24: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/24.jpg)
Minimal Surfaces• Nature uses them for a long time• Discovered by Mathematicians in
the 1970s• Introduced in ANSYS SC, CAD, AM
preprocessors and Generative Design Systems the last couple of years
![Page 25: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/25.jpg)
BiomimicryButterfly wings with Gyroid Topologies
![Page 26: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/26.jpg)
Bio-inspired Lattice Generation
• Bio-inspired hexagonal and square honeycomb structures and lattice materials based on repeating unit cells composed of webs or trusses
Venus flower basket glass sponges Euplectella
![Page 27: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/27.jpg)
Design Option 3 with large Gyroid LatticeDesign Version: Gyroid
Isometric View
![Page 28: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/28.jpg)
CAD Model with fine Gyroid Lattice
Front View
Design Version: Gyroid
![Page 29: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/29.jpg)
CAD Model with fine Gyroid Lattice
Detail View
Design Version: Gyroid
![Page 30: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/30.jpg)
Summary Reverse Engineering Techniques that reduce weight and improve safety margins
Facetted Scanned Part
Load cases and Boundary conditions
Finite Element Results for Load Estimation
Generate optimum shape (stl part)
Generate MBD smooth surface model (Nurbs)
Alternative Design Option 2
Alternative Design Option 3
Parametric Solid Model
![Page 31: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/31.jpg)
Design Challenges to MBD Implementation • Topology Optimization output is a faceted model (.stl)• Automatic CAD reconstruction. This is not trivial (SC
from ANSYS, Sub-D, PTC/Freestyle, Altair/Inspire, Dassault Systems 3DX, SANDIA, etc.)
• Why bother with CAD/NURBS?– Size optimization, morphing, post-processing– Design model, Stock model & CNC assembly – High quality mesh for validation step– In the age of MBD/MBE we need:
• Accurate mass properties• Semantic GD&T• Automated Assembly Tolerance Analyses• Inspection/Verification & process definition for
metrology (QIF)• Technical Data Package (TDP) for NASA & DOD
projects
![Page 32: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/32.jpg)
Design Challenges to AM Implementation • Process regularly produces what would be considereddefects in conventional processes porosity and lack of fusion. Possible root causes are:
– Powder contamination– Unremoved powder– Rough finish on downward facing surfaces– Voids due to lack of fusion and distributed porosity– Process interruptions, spreader impacts on protruding solidified geometry
• Anisotropic & variable mechanical properties• There are “AM design rules” that are different than conventional
manufacturing design rules• Design is not unconstrained by manufacturing
There are AM limitations such as:– Min/Max Wall Thicknesses– Complexity– Wall Pitch, Fillet Radii– “Overhangs”, “Ceilings”– Support Structures– Powder Removal
![Page 33: Generating the Digital Thread for Backlogged Parts that ... · Generating the Digital Thread for Backlogged Parts that Lack TDP • Sometimes . aerospace manufactures . of the defense](https://reader030.vdocuments.us/reader030/viewer/2022040418/5d622ef788c993e7488b75be/html5/thumbnails/33.jpg)
PMI Information for Additive Manufacturing• Material Specification (Alloy composition, Powder
diameter, Powder compaction, Service trace elements)
• Printer & Print Orientation• Manufacturing process settings (Power, Speed,
Layer thickness, hatch spacing, Spot size, Bed & Powder Temperature, etc.)
• Post Processing requirements– Strain Relief– Support Removal– Sanding / grit blasting– Painting / coating– Heat Treatment– Hot Isostatic Press (HIP) cycle
• Surface Finish• Machined Features (Design & Stock Models)• Inspection Dimensions
– Datums– Inspection points for acceptable warping/distortion– Inspection Plan