ansys simulation solution from topology optimization to ...€¦ · lattice design using topology...
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1 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
ANSYS Simulation solution from Topology Optimization to Metal Additive Manufacturing Process
Abel Ramos – Application Engineer
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2 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
ANSYS Vision for Additive Design
Design Space
Engineering Requirements
PrinterParameters
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3 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
AGENDA: Design for AM with ANSYS
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4 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Design for Additive Manufacturing
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5 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Topology Optimization Overview
Given
Design space
Applied load cases, frequency constraints, and other engineering
requirements
Determine
Geometry with maximum stiffness and minimal mass
Subject To
Stress and/or displacement
constraints
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6 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Topological Optimization for Additive Example
• Wheel
In cooperation with TH Ingolstadt / AUDI
6
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7 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Lattice Design Using Topology Optimization
Optimize Lattice Density Distribution− Homogenization-based approach
− Support library of lattice cell templates
− Validate design
− Construct detailed lattice geometry
Design Validation on Homogenized Model
Generate Lattice Structure, Validate Manufacturability
Structural ProblemSet up
Lattice Density Optimization Print
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8 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Topology Optimization WorkflowEnables superior designs via physics-driven free-
form design optimizationTopological
Optimization
Validation
Geometry
Is this design printable?
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9 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Additive Manufacturing
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10 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
What is Additive manufacturing?
Additive Manufacturing (or 3D printing) builds 3D objects byadding a layer-upon-layer of material
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11 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
The AM Promise
• Impossible to Manufacture
• Part Consolidation
• Distributed Production
• New Material Properties
• Replacement parts
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12 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
The AM Promise
• Impossible to Manufacture
• Part Consolidation
• Distributed Production
• New Material Properties
• Replacement parts
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13 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
The AM Promise
• Impossible to Manufacture
• Part Consolidation
• Distributed Production
• New Material Properties
• Replacement parts
Removal of Joints
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14 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
The AM Promise
• Impossible to Manufacture
• Part Consolidation
• Distributed Production
• New Material Properties
• Replacement parts
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15 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
The AM Promise
• Impossible to Manufacture
• Part Consolidation
• Distributed Production
• New Material Properties
• Replacement parts
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16 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
The AM Promise
• Impossible to Manufacture
• Part Consolidation
• Distributed Production
• New Material Properties
• Replacement parts
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17 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Understanding the problem
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18 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Build Issues
It can take multiple build tries until a successful build is obtained
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19 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Build Issues
• Due to the high thermal strains and induced plastic strains, parts distort when removed from the build plate
DISTORTION
BLADE CRASH• The part can distort out of the top of the powder
bed during the build− At worst, the build will stop
− At best, the part will be deformed or the powder bed altered leading to a defect in the part
CRACKING
• The high residual stresses and high strains can lead to cracking in either the part or its supports
Figure courtesy of Dr. Tim Simpson (Penn State University)
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20 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
$5,000
$2,000
$4,000
$3,500$3,000
How to avoid a bucket filled with failed prints, sitting right next to a million-dollar machine.
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21 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Current AM Build Workflow
Design Build Measure
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22 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Why simulation is key to realizing full potential of Additive Manufacturing?
Need Process Simulation toGet it Right the First Time!
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23 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Simulation-Assisted AM Build Workflow
Design Virtual BuildProduction
BuildMeasure
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24 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Process Simulation Goals
Answer the questions about the design:
• Is this buildable?
• What is the thermal distortion?
• How do I compensate the design for the distortion
• What is the best built orientation?
• What are the best support to use, and where?
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25 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Different Types of Customer need AM Simulation
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26 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
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27 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
ANSYS AM products
ANSYS Additive Print
Lightweight, Standalone application
Delivered outside of Workbench • Desktop and Cloud availability
Includes SpaceClaim
Targeted at Designers and Machine Operators
Predict build quality, part distortion, reduce build failures… maximize productivity of your AM machine
Designers
Operators
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28 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
ANSYS AM products
ANSYS Additive Suite
Includes All ANSYS AM capabilities• ANSYS Workbench & Mechanical Enterprise Additive Capabilities
• Process Simulation• Topological Optimization• Lattice Optimization
• Additive Science• Scan-vector-level thermal analysis • In-depth material behavior
• Additive Print
FEA analysts, AM experts and material researchers
Industry leading analysis tool for AM processes and materials
Engineers
Scientists
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29 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Workflow Overview
Static Structural (or Modal)
Problem Set up
Design Optimization
Design Validation
Original Assembly Optimized Part Validate Design
Optimized Geometry
DESIGN PROCESS SIMULATION
Asses Printing Process
Manufacturing Process
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30 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Features of ANSYS AM Suite
• Options for Simplified Thermal Analysis AND Detailed Thermal Analysis
• Topology / Lattice Optimization
• Distortion / Residual Stress / Failure Prediction
• Automatically Compensate Geometry for Distortion
• Four Strain Mode Options
• STL File Repair / Manipulation
• Location-Specific Microstructure Output
• Geometry-based Support Generation
• Physics-based Support Generation
• Porosity Predictions
• Simulate using Machine Scan-Vectors
• Thermal Sensor predictions
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31 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Additive ManufacturingApplication Examples
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32 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
The Pitfalls
On the Build Plate
Simulation with ANSYS Additive Print
(red – shows where the part deforms upwards)
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33 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Why Simulate
Distortion Compensated simulation results (blue) overplayed on STL file
Accurately printed part
Simulation accuratelypredicts distortion
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34 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Application example: Distortion compensation
Compensated GeometryOriginal Geometry
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35 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Comparison of Support Failure Prediction to Experiment
• Support Failure Prediction− Prediction of support failure
for default supports show excellent correlation to experimental results
− Strengthened supports were also correctly predicted to fail
Default Support Failure Prediction
Strengthened Support Failure Prediction
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36 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Summary
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37 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
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38 © 2018 ANSYS, Inc. June 15, 2018 ANSYS Confidential
Design for AM with ANSYS