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Titelmasterformat durch Klicken bearbeiten
© CADFEM 2018
ANSYS Additive Manufacturing
Manfred Maurer
© CADFEM 2018
The Additive Manufacturing Promise
1. Impossible to Manufacture
2. Lightweighting
3. Part Consolidation
4. Multifunctional Designs
5. Distributed Production
6. New Material Properties
7. Replacement Parts
8. Customization
9. …
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© CADFEM 2018
Topology Optimization is not enough
CNC Machined 3D Printed
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Why Simulate?
It can take multiple build attempts until a successful build is obtained
• Excessive distortion
• Recoater arm interference (blade crash)
• Breaking off from supports
• Part fracture
• Lack of fusion (excess porosity)
• Poor microstructure
• …
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Figure courtesy of Dr. Tim Simpson (Penn State University)
A.D. Rollet and Ross Cunningham, NextManufacturing, Carnegie-Mellon University
© CADFEM 2018
Why Simulate?
Distortion Compensated simulation results (blue)
overlayed on STL file of scanned printed part (red)
Accurately printed part
Simulation accurately
predicts distortion
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CHF5000
CHF2000 CHF4000
CHF3500 CHF3000
© CADFEM 2018
Additive Manufacturing Categories
VAT Photopolymerisation
Material Jetting
Binder Jetting
Sheet Lamination
Material Extrusion
Powder Bed Fusion
Directed Energy Deposition
© CADFEM 2018
Metal Additive Manufacturing
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Powder Bed Fusion
Scanner Laser
Powder delivery piston
Fabrication powder bed
Fabrication piston
Powder Delivery system
Object being fabricated
Roller
Image source: Ansys
© CADFEM 2018
Integrated Workflow
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Design for AM with ANSYS
1. Complete Design-to-Print Solution
1. Increased Confidence without
Trial-and-Error
1. Truly Successful AM Production
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Overdesigned
Topo Optimized
Validated
Print process simulation
Physics-based supports
Microstructure analysis
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Integrated Workflow Part 1:
Topology Optimization
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Optimal Design via Topology Optimization
Base Model
Design space
Loadcases
Topology-
optimization
Smoothing
.stl
CAD reverse
engineering Meshing
Validation Source: CADFEM Medical
PRINT 12
© CADFEM 2018
Optimal Design via Topology Optimization
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Integrated Workflow Part 2:
Fast Process Simulation for
Print Optimization
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Fast Process Simulation
• For the Process Engineer and Machine Operator: ANSYS Additive Print
• Optimize Process:
• Find good print direction
• Find good support strategy
• Find good print parameters
• “Inherent Strain” approach
• Fast simulation fast decision making
• Goal: Avoid failed prints
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ANSYS Additive Print
Software GUI
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© CADFEM 2018
Application example: Distortion compensation
Compensated Geometry Original Geometry
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© CADFEM 2018
Blade Crash Prediction
As the part is being build, the recoater blade may run into the part
– damaging the part, and potentially the machine
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Automatic support structures
• Automatically generated physics based support structures
• Residual stresses after support removal
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Integrated Workflow Part 3:
In Depth Process Simulation for
Product Development
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• For the Development Engineer: ANSYS Mechanical Additive Process Simulation
• Familiar Mechanical interface
• Take advantage of full parametrization
• Include postprocessing steps after process simulation (heat treatment, HIP)
• Include simulation of part function after process simulation
• Coupled transient thermal and static analysis
• Goal: Optimize process AND part design
Detailed Process Simulation
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ANSYS Mechanical Additive Process Simulation
Workbench/Mechanical integrated, Wizard based setup
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ANSYS Mechanical Additive Process Simulation
Individual support structures, print orientation, process parameters…
Print direction
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ANSYS Mechanical Additive Process Simulation
Temperature Displacement Stress
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© CADFEM 2018
ANSYS Mechanical Additive Process Simulation
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Mesh Temperature Displacement
© CADFEM 2018
ANSYS Mechanical Additive Process Simulation
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Stresses Displacement Stresses
© CADFEM 2018
Summary
• Topology Optimization has been around for a long time
• So does its software implementation!
• Advances in AM make it possible to overcome the past difficulties
• New manufacturing challenges come with AM
• Fast advances in Software make it possible to tackle these
challenges!
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Overview: ANSYS AM Process
1°
44°
Initial Design
Topology Optimization
STL Cleanup
Function Check
AM Process Simulation
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© CADFEM 2018
Thank you for your attention!
Dr. sc. (ETH) Manfred Maurer
+41 (0)52 368 01 39
Simulation ist mehr als Software
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