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MSC Solutions for Additive Manufacturing
Simufact Additive
15.01.2018
MSC Software Confidential 2
Simufact Product Portfolio
Hot ForgingCold FormingSheet Metal
Forming
Mechanical
Joining
Ring RollingRollingOpen Die
Forging
Heat
Treatment
Laser BeamArc WeldingElectron
Beam
BrazingResistance
Spot WeldingStress Relief
Powder Bed Fusion
Metal Deposition
MSC Software Confidential 3
What is Laser Powder Bed Fusion?
• Coating the surface with powder
• ca. 20-100 µm layer thickness
• Selective melting by laser
• Lower build platform
• Repeat …
• Shielding Gas (Argon) required
• ~200-2000W
• Size capacity 50³-500³ mm³
• Build Rate capacity 25-100 cm³/h
• Al, Ti, St, CoCr, Ni-Base
• High residual stresses possible
• Critical deformations possible
• Many support structures required
• Machines: EOS, SLM, Concept Laser, Renishaw, Realizer,
Trumpf, 3D Systems, Additive Industries, …
AM Technical Training
November 2nd 2016 simufact additive 1.0Marc
simufact additive
MSC Software Confidential 6
Why AM?
• Rapid Prototyping and making small batches of parts.
• Design parts that would otherwise be impossible to manufacture –
Reduced manufacturing constraints
• Lower material usage either by design or because of less waste
material
• Lower Energy Usage – eliminate production step, no energy use
for removal of material.
• Light weighting
• Manufacture assemblies without the need to assemble multiple
parts, reducing part inventory.
• No need for tooling
• Agility to manufacture parts anywhere / Print on Demand /
Customization
• Repair of parts
• Ability to make functionally graded materials (FGM)
MSC Software Confidential 7
AM Examples
©
Citim
Complex structures not manufacturable
with other technology
Small Lots down
to Individual Parts
Reduce
Weight
Reduce costs by toolless manufacturing
Saves resources >
low waste ratio,
reuse powder
AM Technical Training
November 2nd 2016 simufact additive 1.0
Functional
Integration
Integral Parts >
Reduce Number of Parts
MSC Software Confidential 8
Manufacturing Challenges
• Distortion Part outside of Tolerances
• Residual Stresses Part or Support Failure
• Too large height distortion Build Job Failure
• Iterative Trial and Error
• Lost Time and Money
Simulation
• Reduce Trial and Error
• Faster, Better, Cheaper
Source: NDES
simufact additive 1.0
Source: NDES EPSRC
MSC Software Confidential 9
AM Simulation Primer – Dimension Scale
• Grain size
– 0.001 – 0.05 mm (steel)
• Powder size
– EBM - 0.04 – 0.10 mm
– SLM - 0.015 – 0.05 mm
– LENS – 0.025 – 0.05 mm
• Layer Thickness
– Metal Powder 0.15 – 0.2
– Metal DMD 0.10 – 0.20 mm
– Plastic FDM - 0.2 -0.5 mm
• Melt Pool – 0.1 – 0.2 mm
• Part - 50 – 500 mm
• Number of layers 1000 - 4000
MSC Software Confidential 11
Hatching
• Manufacturing is dependent upon Hatching
MSC Software Confidential 12
Analysis Approaches
• Micro scale
– Examine each particle
– Examine fluid behavior in melt
pool
– Track each hatch line
•Moving heat source
•Transient fully thermo-mechanically
metallurgical coupled
•Delivers thermal history and derived
results like microstructure
MSC Software Confidential 13
Analysis Approaches
• Meso scale
– Group multiple hatch lines
– Group multiple layers
– Thermal Heater Model
•Element layer analysed in one step or
by hatching segments
•Thermal, mechanical or thermo-
mechanically coupled
•Able to deliver approximate thermal
history and derived results
MSC Software Confidential 14
Analysis Approaches
• Macro Model
– Conventional structural
elements size
– Bulk Material Properties
– Inherent Strain
•Element layer (> powder layer)
analyzed in one step
•Inherent Strains - pure mechanically,
extremely fast
•Delivers Distortion & Stress
Comprise
– Plastic strains
– Thermal strains
– Creep strains
– Phase transformation
strains
Reflect
– Material
– Manufacturing
parameters
– (Individual) machine
MSC Software Confidential 16
Analysis Scales
• Element layer analysed in one step or
by hatching segments
• Thermal, mechanical or thermo-
mechanically coupled
• Able to deliver approximate thermal
history and derived results
• Moving heat source
• Transient fully thermo-mechanically
metallurgical coupled
• Delivers thermal history and derived
results like microstructure
• Element layer (> powder layer)
analyzed in one step
• Inherent Strains - pure mechanically,
extremely fast
• Delivers Distortion & Stress
micro scale meso scale macro scale
Information
Exchange
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Our Answer – Metal AM Simulation
Process Chain Coverage
We aim at covering a wide range of the AM process chain:
• Creating the Part by Additive Manufacturing
• Stress Relief by Heat Treatment
• Cutting the Part off the Base Plate
• Removal of Supports
• Hot Isostatic Press Treatment (only mechanical for the start)
AM Technical Training
November 2nd 2016 simufact additive 1.0
MSC Software Confidential 18
Voxel Technique with Solid Fraction
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Equivalent stress
Virtually Explore the Complete Process Chain
baseplate removedadditively manufactured
removal of supportsafter cooling
after heat treatment
after HIP process
MSC Software Confidential 20
Virtually Explore the Influence of:
Parameter Set 1 Parameter Set 2
• Cutting direction & supports
removal sequence
• Manufacturing
parameters & materials
MSC Software Confidential 21
Virtually Explore the Influence of:
• Support structure configuration
Vertical Horizontal
Less Support Max Support
• Build orientation
Validation Examples
MSC Software Confidential 23
Validation Example
MSC Software Confidential 24
Calibration of Inherent Strain by Simple Cantilever Build
Step 1: Build cantilevers Cut Measure tip displacement
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Our Answer – Metal AM Simulation
Cutting in yCutting in x
Parameter Set 1 Parameter Set 2
AM Technical Training
November 2nd 2016 simufact additive 1.0
Step 2: Automatic calibrationStore in database
MSC Software Confidential 26
Validation Example
Simulation Actual Part
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Validation Example
Cutting in x
Parameter Set 1
NDES
NDES
NDES
MSC Software Confidential 28
Validation Example
Parameter Set 1
ExperimentSimulationDistortions
Scaled displacement = 10x
1 2 3
Point Simulation (mm) Experiment (mm)
1 0.3539 0.3532
2 0.5527 0.5517
3 0.5931 0.5920
Cross Section Contour Distortion
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Total Solution
• Manufacture
• Heat Treatment
• Cooling
• Remove supports
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Complex Manifold
Renishaw
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Demonstration
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More Information
• http://www.mscsoftware.com/product/simufact-additive
• http://www.simufact.com/additive-manufacturing.html
• http://www.mscsoftware.com/product/marc
Thank You