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© CADFEM 2017 ANSYS Additive Manufacturing

Journée Technologique AddiPole Nouveautés ANSYS pour le calcul structurel et l’impression 3D



Structural design with ANSYS

© CADFEM 2017

Additive manufacturing

Functionality

Load cases

ANSYS Additive Manufacturing

© CADFEM 2017

Your Cyber Physical System = Digital & Hardware Twins


Robust Design Optimization RDO

Modules Integration

High rate throughput

Controls, logics, delays

…

Stochastic variations

Tolerances

Prescriptive analytics

…

Metamodels, MOR, Co-simulation, Strong Matrix coupling

product

© CADFEM 2017

ANSYS Mechanical


• Linear and non-linear structural

mechanics

• Contact analysis with and without

friction

• All kinds of non-linear material

properties

• Large deflection and stability analysis

• Bolt pretension analysis

• Thermal stress analysis

• Multiple load steps

• Limit load analysis

Large deflection analysis with non-linear

contact and plastic deformation

Equivalent

plastic strain

Equivalent v.

Mises stress

ANSYS Mechanical Solutions

© CADFEM 2017

Element Technology


• Complete and consistent suite of

structural elements

• Beam

• Shell, SolidShell

• Solid

• Contact

• Spring, Damper

• …

• ANSYS Workbench automatically

assigns appropriate element type

Solid-model Shell-model

MPC connection

Hybrid Solid-Shell model


© CADFEM 2017

Contact Analysis


Contact

pressure Deformation


© CADFEM 2017

Material Modeling


• Material models for all kinds of material (> 60 models)

• Metal, Rubber, Plastic

• Composites

• Time dependent (Creep)

• Temperature dependent

Element

Technology

Shape Memory Alloys Metal

Inelasticity

Rubber

Elasticity

Drucker-Prager

Plasticity

Rate-Independent

Behavior Rate-dependent

Behavior Anisotropic

Behavior Rate-Independent

Behavior

Rate-dependent

Behavior

Deformation Plastic Strain


© CADFEM 2017

Analysis of Thin Bodies – Shell Meshing


• Shell meshing requires the

extraction of a mid-surface model

from an existing 3D-CAD geometry

• Mid-surfacing may need

considerable time in case of large

complex geometries

• The shell thickness is automatically

extracted from original geometry

3D CAD Geometry Mid-surface model

Shell

Mesh


© CADFEM 2017

Bolt Pretension Analysis


• Bolt pretension analysis

• First step: pretension calculation

• Second step: load analysis

• Stepped bolt pretension

Contact Pressure

Load step definition and

convergence of non-linear

contact analysis


© CADFEM 2017

Structural Dynamics – Harmonic Analysis


• Harmonic analysis yields displacement

and stresses as a function of frequency

• A harmonically varying forces or

displacements can be applied

• Includes pre-stress effects and damping

Harmonic Response

3. Eigenfrequency 4. Eigenfrequency


© CADFEM 2017

Structure dynamics (2D,3D): several components (compliance, integrity, feeling)

ANSYS Additive Manufacturing source: CADFEM

© CADFEM 2017

Rigid/Flexible Dynamics


• A dynamic analysis in time

domain is required if non-linear

effects have to be accounted for

• Large deformation

• Non-linear contact

• Non-linear material behavior

• Fast rigid body transient analysis

• Combination of rigid and flexible

bodies

• Flexible body analysis numerically

considerably more expansive


© CADFEM 2017

Explicit Dynamics


• Easy access to explicit structural mechanics for ANSYS users

• Simulation of large nonlinear and transient

dynamic problems with LS-DYNA or Autodyn

• Drop test

• Manufacturing, Forming

• Load Limit Analysis including material failure


© CADFEM 2017

Fatigue - Life



© CADFEM 2017

ANSYS Thermal


• Static and transient analysis

• Radiation

• Phase change

• Thermal contact analysis

• Thermal stress analysis

Thermal Contact Analysis

271 parts

554 contact pairs

Thermal Analysis of an Engine Block

Thermal Analysis of an Exhaust

System

© CADFEM 2017

For non experts: Discovery live


© CADFEM 2017

Example

• Optimization of a pitch arm of a

helicopter rotor head



DEMO: Pitch Arm with Discovery Live



Topology Optimization

© CADFEM 2017

Optimal Design via Topology Optimization

Base Model

Design space

Loadcases

Topology-

optimization

Smoothing

.stl

CAD reverse

engineering Meshing

Validation Source: CADFEM Medical

PRINT ANSYS Additive Manufacturing

© CADFEM 2017

Lattice Structures (Beta)


© CADFEM 2017

Example : Pitch Arm



DEMO: Pitch Arm Topo Opti

© CADFEM 2017

STL Preparation for Additive Manufacturing


Coarse demo Fine

© CADFEM 2017

ANSYS SpaceClaim for Additive Manufacturing

• Dedicated tools to:

• Clean/repair models before printing

• Holes, self-intersections, connections, duplicates, sharps

• Prepare models

• Boolean, split, shell, infill, thicken, smooth

• Analyzing printability:

• Thickness, overhangs

• Edit not just repair!

• Unique hybrid modeling (CAD +facets in one environment)

• Sketch new geometry to add/remove/improve facets


© CADFEM 2017

ANSYS SpaceClaim for Additive Manufacturing

• New Skin Surface tool for interactive surface fitting to faceted models.

5 seconds


© CADFEM 2017

ANSYS SpaceClaim For Reverse Engineering

• Dedicated tools to:

• Fit curves to mesh cross-sections

• Fit basic shapes:

• Planes, cylinders, spheres

• Fit surfaces to selected regions

• Reference Modeling

• Pull ‘Up To’ mesh regions:

• Fillets, extrusions, revolves

• Select mesh regions by similar curvature

• Select mesh edges (directional, open, etc)

• Sketch on mesh


© CADFEM 2017

Geometry conversion

• Detail (Redesigning)


© CADFEM 2017

Validation System

• Stress „Original“

,


© CADFEM 2017

Validation System

• Stress „Optimized “

,


© CADFEM 2017

Validation System

• Comparison

0

10

20

30

40

50

60

70

80

90

100

Mass [%] Deformation [%] Stress [%]

Original

Optimized




ANSYS Additive Print

Fast Process Simulation for Print Optimization

© CADFEM 2017

Fast Process Simulation

• For the Process Engineer and Machine Operator:


• Optimize Process:

• Find good print direction

• Find good support strategy

• Find good print parameters

• Goal:

Avoid failed prints


© CADFEM 2017


Software GUI


© CADFEM 2017

Application example: Distortion compensation

Compensated Geometry Original Geometry


© CADFEM 2017

Blade Crash Prediction

As the part is being build, the recoater blade may run into the part

– damaging the part, and potentially the machine


© CADFEM 2017

Automatic support structures

• Automatically generated physics based support structures

• Residual stresses after support removal



DEMO: PRINT



ANSYS Additive Suite Workbench Additive Capabilities / Mechanical Additive Process Simulation (MAPS)

Additive Science …for experts

© CADFEM 2017

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



DEMO: Pitch Arm AM

© CADFEM 2017

ANSYS Mechanical Additive Process Simulation

Individual support structures, print orientation, process parameters…

Print direction


© CADFEM 2017

ANSYS Mechanical Additive Process Simulation • Manual support structure changes:

• Maybe you want to avoid that support is placed on top of the build part

• Own support structure

• Getting rid of very small or unreasonable support structures

• In doing so, pay attention to sharp angles without fillets that are not identified by the overhang angle search

function


© CADFEM 2017


• Detect and generate support for an overhang angle of 45° => yields a more

realistic support structure:


© CADFEM 2017

Lumped Layer Approach

Global model heat source

Applying the power by using temperature T

Simulation (ANSYS):

Power (Time)

Temperature (Time)

Power

Simulation-time

Temperature

Simulation-time

Reality:

Power (Time)

Temperature (Time)

Power

Zeit

Temperature

Zeit

Disadvantage: not conforming to time

1 layer: ΔT E = ΔT • V • c • ρ

2 layers: ΔT E = 2 • ΔT • V • c • ρ

1 layer: Q, Δt E = Q • Δt

100 layers: Q, Δt E = 100 • Q • Δt

This way is used in ANSYS ANSYS Additive Manufacturing

© CADFEM 2017

How to adapt this solution to special simulation requirements

• amtype,PBF

• This specifies the additive manufacturing process type. In this case it is Powder Bed

Fusion. It is also possible to specify Direct Energy Deposition (DED)


Apply Powder Layer Lower Base Plate

Exposure

Powder Bed Fusion

© CADFEM 2017

Roadmap

January 2018

New Features

19 (March 2018)

New Features

19.1 (May 2018)

New Features

19.2 (Sept 2018)

New Features

20.X (2019)

New Features

AD

DIT

IVE

SU

ITE

ADDITIVE

PRINT Stand Alone Product,

bundled with SpaceClaim

• Included as a Stand-Alone

Product

• DESKTOP Availability

• ANSYS Viewer integration • HPC for Local Parallelization

• Import Externally Generated

Supports

• ANSYS Workbench (beta)

Integration (Optional)

• Advanced Support Generation • Build Platform Optimization • Heat Treatment • HPC Distributed Parallelization • Full Mechanical Enterprise

Integration

• Lattice-based Support

Structure Optimization

WORKBENCH

ADDITIVE

CAPABILITIES

• Mechanical Process

Simulation (beta)

• SpaceClaim Lattice

Construction & faceted data

handling

• Topological Optimization

• Full Product Release

• Lattice Optimization

• Support Generation

• Heat Treatment (beta)


Structure Optimization (beta)

• Heat Treatment


Structure Optimization

ADDITIVE

SCIENCE • CLOUD Availability (Beta)

• Cloud (w/ANSYS Viewer) and

Desktop (beta)

• Full Release of DESKTOP

Stand-Alone

• Microstructure Predictions

• Workbench Integration (beta)

• Full Mechanical Enterprise

Integration

• Microstructure Based

Property Predictions

• Machine Process Parameter

Development Toolkit

Requires Mechanical Enterprise License ANSYS Additive Manufacturing

© CADFEM 2017

Take Home: ANSYS AM Process

1°

44°

… ?

Design with Physics insights

(Discovery Live)

Topology Optimization

STL Cleanup

QS Check

AM Process Simulation


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