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© 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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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

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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

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Additive Manufacturing Categories

VAT Photopolymerisation

Material Jetting

Binder Jetting

Sheet Lamination

Material Extrusion

Powder Bed Fusion

Directed Energy Deposition

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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

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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

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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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Application example: Distortion compensation

Compensated Geometry Original Geometry

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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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ANSYS Mechanical Additive Process Simulation

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Mesh Temperature Displacement

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ANSYS Mechanical Additive Process Simulation

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Stresses Displacement Stresses

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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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Thank you for your attention!

Dr. sc. (ETH) Manfred Maurer

manfred.maurer@cadfem.ch

+41 (0)52 368 01 39

Simulation ist mehr als Software

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