MSC Solutions for Additive ... - MAGIC ENGINEERING€¦ · MSC Software Confidential 3 What is...

MSC Solutions for Additive Manufacturing

Simufact Additive

15.01.2018

MSC Software Confidential 2

Simufact Product Portfolio

Hot ForgingCold FormingSheet Metal

Forming

Mechanical

Joining

Ring RollingRollingOpen Die

Forging

Heat

Treatment

Laser BeamArc WeldingElectron

Beam

BrazingResistance

Spot WeldingStress Relief

Powder Bed Fusion

Metal Deposition


What is Laser Powder Bed Fusion?

• Coating the surface with powder

• ca. 20-100 µm layer thickness

• Selective melting by laser

• Lower build platform

• Repeat …

• Shielding Gas (Argon) required

• ~200-2000W

• Size capacity 50³-500³ mm³

• Build Rate capacity 25-100 cm³/h

• Al, Ti, St, CoCr, Ni-Base

• High residual stresses possible

• Critical deformations possible

• Many support structures required

• Machines: EOS, SLM, Concept Laser, Renishaw, Realizer,

Trumpf, 3D Systems, Additive Industries, …

AM Technical Training

November 2nd 2016 simufact additive 1.0Marc

simufact additive


Why AM?

• Rapid Prototyping and making small batches of parts.

• Design parts that would otherwise be impossible to manufacture –

Reduced manufacturing constraints

• Lower material usage either by design or because of less waste

material

• Lower Energy Usage – eliminate production step, no energy use

for removal of material.

• Light weighting

• Manufacture assemblies without the need to assemble multiple

parts, reducing part inventory.

• No need for tooling

• Agility to manufacture parts anywhere / Print on Demand /

Customization

• Repair of parts

• Ability to make functionally graded materials (FGM)


AM Examples

©

Citim

Complex structures not manufacturable

with other technology

Small Lots down

to Individual Parts

Reduce

Weight

Reduce costs by toolless manufacturing

Saves resources >

low waste ratio,

reuse powder


November 2nd 2016 simufact additive 1.0

Functional

Integration

Integral Parts >

Reduce Number of Parts


Manufacturing Challenges

• Distortion Part outside of Tolerances

• Residual Stresses Part or Support Failure

• Too large height distortion Build Job Failure

• Iterative Trial and Error

• Lost Time and Money

Simulation

• Reduce Trial and Error

• Faster, Better, Cheaper

Source: NDES

simufact additive 1.0

Source: NDES EPSRC


AM Simulation Primer – Dimension Scale

• Grain size

– 0.001 – 0.05 mm (steel)

• Powder size

– EBM - 0.04 – 0.10 mm

– SLM - 0.015 – 0.05 mm

– LENS – 0.025 – 0.05 mm

• Layer Thickness

– Metal Powder 0.15 – 0.2

– Metal DMD 0.10 – 0.20 mm

– Plastic FDM - 0.2 -0.5 mm

• Melt Pool – 0.1 – 0.2 mm

• Part - 50 – 500 mm

• Number of layers 1000 - 4000


Hatching

• Manufacturing is dependent upon Hatching


Analysis Approaches

• Micro scale

– Examine each particle

– Examine fluid behavior in melt

pool

– Track each hatch line

•Moving heat source

•Transient fully thermo-mechanically

metallurgical coupled

•Delivers thermal history and derived

results like microstructure


Analysis Approaches

• Meso scale

– Group multiple hatch lines

– Group multiple layers

– Thermal Heater Model

•Element layer analysed in one step or

by hatching segments

•Thermal, mechanical or thermo-

mechanically coupled

•Able to deliver approximate thermal

history and derived results


Analysis Approaches

• Macro Model

– Conventional structural

elements size

– Bulk Material Properties

– Inherent Strain

•Element layer (> powder layer)

analyzed in one step

•Inherent Strains - pure mechanically,

extremely fast

•Delivers Distortion & Stress

Comprise

– Plastic strains

– Thermal strains

– Creep strains

– Phase transformation

strains

Reflect

– Material

– Manufacturing

parameters

– (Individual) machine


Analysis Scales

• Element layer analysed in one step or

by hatching segments

• Thermal, mechanical or thermo-

mechanically coupled

• Able to deliver approximate thermal

history and derived results

• Moving heat source

• Transient fully thermo-mechanically

metallurgical coupled

• Delivers thermal history and derived

results like microstructure

• Element layer (> powder layer)

analyzed in one step

• Inherent Strains - pure mechanically,

extremely fast

• Delivers Distortion & Stress

micro scale meso scale macro scale

Information

Exchange

MSC Software Confidential 1717 MSC Software Confidential

Our Answer – Metal AM Simulation

Process Chain Coverage

We aim at covering a wide range of the AM process chain:

• Creating the Part by Additive Manufacturing

• Stress Relief by Heat Treatment

• Cutting the Part off the Base Plate

• Removal of Supports

• Hot Isostatic Press Treatment (only mechanical for the start)




Voxel Technique with Solid Fraction


Equivalent stress

Virtually Explore the Complete Process Chain

baseplate removedadditively manufactured

removal of supportsafter cooling

after heat treatment

after HIP process


Virtually Explore the Influence of:

Parameter Set 1 Parameter Set 2

• Cutting direction & supports

removal sequence

• Manufacturing

parameters & materials


Virtually Explore the Influence of:

• Support structure configuration

Vertical Horizontal

Less Support Max Support

• Build orientation

Validation Examples


Validation Example


Calibration of Inherent Strain by Simple Cantilever Build

Step 1: Build cantilevers Cut Measure tip displacement


Our Answer – Metal AM Simulation

Cutting in yCutting in x

Parameter Set 1 Parameter Set 2



Step 2: Automatic calibrationStore in database


Validation Example

Simulation Actual Part


Validation Example

Cutting in x

Parameter Set 1

NDES

NDES

NDES


Validation Example

Parameter Set 1

ExperimentSimulationDistortions

Scaled displacement = 10x

1 2 3

Point Simulation (mm) Experiment (mm)

1 0.3539 0.3532

2 0.5527 0.5517

3 0.5931 0.5920

Cross Section Contour Distortion


Total Solution

• Manufacture

• Heat Treatment

• Cooling

• Remove supports


Complex Manifold

Renishaw


Demonstration


More Information

• http://www.mscsoftware.com/product/simufact-additive

• http://www.simufact.com/additive-manufacturing.html

• http://www.mscsoftware.com/product/marc

http://www.mscsoftware.com/product/simufact-additive

http://www.simufact.com/additive-manufacturing.html

http://www.mscsoftware.com/product/marc

Thank You

MSC Solutions for Additive ... - MAGIC ENGINEERING€¦ · MSC Software Confidential 3 What is...

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