How Software helps drive the industrialization of Additive ... · How Software helps drive the...

How Software helps drive theindustrialization of AdditiveManufacturingTom van ‘t Erve; Director Development; Siemens Industry Software (DF PL MFE)

Realize innovation.Unrestricted © Siemens AG 2017

Unrestricted © Siemens AG 2017

Siemens PLM Software

Siemens Power GenerationGas turbine is a focal area for the use of Additive Manufacturing

Combustion SystemBurner

Swirler/Nozzle/Filter/Mixer

TurbineBlades & Vanes

High Tech Components with complex design and high potential to improve customer value (efficiency,durability)



Rapid Prototyping use caseSLM SGT-400 CT Blade 1

https://www.youtube.com/watch?v=8vtLtu4ZYsQ



Challenges: Industrializing Additive Manufacturing

Disconnectedsoftware

Multipledata conversions

Uncontrolledworkflow

DESIGNSOFTWARE

SIMULATIONSOFTWARE

PRINT PREPARATIONSOFTWARE

PRODUCTIONSOFTWARE

Conventionalthinking Certification



Siemens PLM Vision:One integrated end-to-end system for industrializing Additive Manufacturing

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Design Simulate 3D Print

Data Management and Shop Floor Connectivity

Siemens Production Software and MES Systems

Partnerships

NX and Simcenter

Teamcenter

Simatic IT

Smart model-driven process



Design for Additive Manufacturing

ConvergentModeling™Technology

Work directly on a mix of faceted andexact solid Brep geometry within a single

model

Unlimited flexibility to designinnovative products

No need for reverse engineering



Design for Additive ManufacturingConvergent Modeling™ Technology - Demonstration

https://www.youtube.com/watch?v=WaZZpey7tJ0




TopologyOptimization

All operations in NX CAD

Multiple load cases

Optimized model can be refined withConvergent Modeling




Lattices*

Lightweight componentsand structural integrity

Integrated latticestructure development

* Available soon




Design RulesEnsure the manufacturability by

checking:Wall Thickness

Overhang Angles requiring supportsEnclosed voids

Avoid costly re-design when a part isdesigned and found to be inadequate

during manufacturing




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Design Simulate 3D PrintNX and Simcenter



Partnerships

Teamcenter

Simatic IT




Simulate for Additive Manufacturing

PREDICT PERFORMANCE

• Optimize part design with advancedanalysis tools

• Validate product performance• Simulate additive processes



Simulate for Additive Manufacturing: Validation for impact of additive processExample: Simulate powder bed processes – micro scale

Energy transfer

Particle Flow / Filling (Discrete Element Modeling – DEM)Powder manufacture and powder bed distribution

Melting / Solidification (Volume of Fluid – VOF)Powder melting simulation (e.G. EBM)




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Partnerships

Teamcenter

Simatic IT




Partnering with leading Additive Manufacturing OEMs

Metal deposition

Released

Plastic fused deposition modeling (FDM)Scheduled for

2017

Metal powder bed Plastic 3D printingScheduled for

early 2017

Soon to beannounced

Released



Siemens and DMG MORI - Hybrid Manufacturing SolutionMulti-axis deposition combined with NC Machining

Available for 3 machine configurations:• LASERTEC 65 3D• LASERTEC 65 3D FD version• LASERTEC 4300 3D

All machines are equipped with Sinumerik 840D SL

Solution components:• LASERTEC machine tool (DMG MORI)• NX CAM Hybrid Additive software (Siemens)

• Additive Multi-axis deposition manufacturing package• Advanced 2-5 Axis Milling package• Postprocessor and Simulation



DMG MORIAerospace Casing - Demo

https://www.youtube.com/watch?v=L3CkzQQFZXs




Metal deposition

Released


2017

Metal powder bed Plastic powder bedScheduled for

early 2017

Soon to beannounced

Released



Powder bed fusion – typical workflow

A model-driven process in NX

Position / nest partson build tray

Create supportstructures

Define the buildstrategies

Verify the laserpath

Select a 3D printer

Design model

Drive 3D printers

Printed part



Post-processing

Integrated NX CAM

Produce high quality partswith precise toolpaths

Automate NC programming

Program any part using a wide rangeof capabilities

All in one system



3D PrintHP Multi Jet Fusion Technology – NX demo




Metal deposition

Released


2017

Metal powder bed Plastic powder bedScheduled for

early 2017

Soon to beannounced

Released



Multi-Axis Fused Deposition Modeling

Build composite parts in various sizes

Leverage robots flexibilityto print parts of any complexity

Eliminate support structures



Multi-Axis Fused Deposition ModelingRobotic composite 3D demonstrator

Integration of Stratasys’ advanced extrusion technology, Siemens MC industrial motion platformand Siemens PLM design-to-product workflow

https://www.youtube.com/watch?v=u_pSEhF3q3Q




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Partnerships

Teamcenter

Simatic IT




Deliver the correct data to production

Establish a closed-loop process


Manage all the manufacturing dataManage access; revisions; workflowsRe-use proven data and processes

Single source of data Connect engineering to the shop floor



Manufacturing Operations ManagementEmbed Additive Manufacturing activities in the overall production process

Manage all pre / post3D printing operations

Order management

Additive Manufacturing managementOperator guidance and checklistPrint job file managementPowder and substrate management

Full production data tracking

* Available soon



Siemens PG Finspång – Burner Tip Repair use caseWork Order Management

Work Order information for burner tip repair is retrieved from SAPand a Work Order (typically for 30 burners) is generated in MES.

• The list of Serial Numbers is associated with the Work Order

• The Work Order is based on a fixed production processconsisting of 14 steps including all operations: preparation, AMand post-processing

• The production coordinator dispatches Work Orders according topriority and work load.

Contextualize AM within the whole production process.

Rapid RepairBurner

2



Siemens PG Finspång – Burner Tip Repair use caseOperator Guidance

Shop-Floor Operators are guided step-by-step in their dailyactivity, in terms of:

• What operation to execute, according to priority and constraints.

• Instructions about how to perform the task at hand: documents,pictures, resources, etc.

• What data to insert/upload for traceability purposes.

Select the correct revision of the Print Job File fromTeamcenter and transfer it to the EOS machine



Siemens PG Finspång – Burner Tip Repair use caseActivity Report / Traceability

Upon completion of activity on all Serial Numbers, the Work Orderswitches automatically to COMPLETED status and is taken out ofthe queue for shop-floor operators.

An activity report is available by Work Order Identifier and bySerial Number.

Detailed reporting.



Conclusions

• Additive Manufacturing is introducing revolutionary new manufacturing capabilities

• The industrialization of Additive Manufacturing requires software that addresses the specific AMrequirements for Product Design, Product Performance Simulation, Manufacturing as well as Data &Manufacturing Operations Management

• Support for these specific Additive Manufacturing requirements has to be an integral part of the PLMtechnology suites that are already established in the industry

• The PLM vendors, including Siemens PLM, were not the first to join, but they understand therequirements that have to be met to take Additive Manufacturing out of the laboratory

• Convergent Modeling technology and manufacturing planning that is associative to the design willenable concurrent engineering and minimize rework

• We @ Siemens “eat our own dog food”



dr. ir. A.H. (Tom) van ‘t ErveDirector Development - NX CAM Machinery and Automation

Siemens Industry SectorSiemens Industry Software B.V.

Industrieplein 3, Gebouw 57553 LL Hengelo, NetherlandsTel. :+31 (74) 2556 271Mobile :+31 (6) 4898 [email protected]

www.siemens.com/plm

Thank you

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