MSC Solutions for Additive Manufacturing Simufact Additive

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Elijah Randall
5 years ago
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1 MSC Solutions for Additive Manufacturing Simufact Additive

Simufact Product Portfolio Cold Forming Hot

Forging Heat Treatment Resistance Spot Welding

2 Simufact Product Portfolio Cold Forming Hot Forging Sheet Metal Forming Mechanical Joining Powder Bed Fusion Arc Welding Laser Beam Electron Beam Rolling Ring Rolling Open Die Forging Heat Treatment Resistance Spot Welding Brazing Stress Relief Metal Deposition MSC Software Confidential 2

20-100 µm layer thickness Selective melting by laser Lower

~200-2000W AM Technical Training simufact additive

0 Marc Size capacity 50³-500³ mm³ Build Rate capacity

stresses possible Critical deformations possible Many

3 What is Laser Powder Bed Fusion? Coating the surface with powder ca µm layer thickness Selective melting by laser Lower build platform Repeat Shielding Gas (Argon) required ~ W AM Technical Training simufact additive November 2nd 2016 simufact additive 1.0 Marc Size capacity 50³-500³ mm³ Build Rate capacity 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, MSC Software Confidential 3

Why AM? Rapid Prototyping and making small batches of parts.

Lower material usage either by design or because of less waste material Lower Energy Usage eliminate

Light weighting Manufacture assemblies without the need to assemble multiple parts, reducing part

4 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) MSC Software Confidential 6

5 AM Examples Functional Integration Integral Parts > Reduce Number of Parts Complex structures not manufacturable with other technology Small Lots down to Individual Parts Citim Reduce costs by toolless manufacturing Saves resources > low waste ratio, reuse powder Reduce Weight AM Technical Training November 2nd 2016 simufact additive 1.0 MSC Software Confidential 7

Manufacturing Challenges Distortion Part

Part or Support Failure Too large height

6 Manufacturing Challenges Distortion Part outside of Tolerances Residual Stresses Part or Support Failure Too large height distortion Build Job Failure Source: NDES Iterative Trial and Error Lost Time and Money Simulation Reduce Trial and Error Faster, Better, Cheaper Source: NDES simufact additive 1.0 EPSRC MSC Software Confidential 8

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.

7 AM Simulation Primer Dimension Scale Grain size mm (steel) Powder size EBM mm SLM mm LENS mm Layer Thickness Metal Powder Metal DMD mm Plastic FDM mm Melt Pool mm Part mm Number of layers MSC Software Confidential 9

8 Hatching Manufacturing is dependent upon Hatching MSC Software Confidential 11

9 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 MSC Software Confidential 12

10 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 thermomechanically coupled Able to deliver approximate thermal history and derived results MSC Software Confidential 13

11 Analysis Approaches Macro Model Conventional structural elements size Bulk Material Properties Inherent Strain Comprise Plastic strains Thermal strains Creep strains Phase transformation strains Reflect Material Manufacturing parameters (Individual) machine Element layer (> powder layer) analyzed in one step Inherent Strains - pure mechanically, extremely fast Delivers Distortion & Stress MSC Software Confidential 14

12 Analysis Scales Information Exchange 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 Element layer analysed in one step or by hatching segments Thermal, mechanical or thermomechanically coupled Able to deliver approximate thermal history and derived results micro scale meso scale macro scale MSC Software Confidential 16

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

13 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) AM Technical Training November 2nd 2016 simufact additive 1.0 MSC 17 Software MSC Confidential Software Confidential 17

14 Voxel Technique with Solid Fraction MSC Software Confidential 18

15 Virtually Explore the Complete Process Chain additively manufactured baseplate removed after heat treatment after cooling removal of supports Equivalent stress after HIP process MSC 19 Software MSC Confidential Software Confidential 19

16 Virtually Explore the Influence of: Manufacturing parameters & materials Parameter Set 1 Parameter Set 2 Cutting direction & supports removal sequence MSC Software Confidential 20

17 Virtually Explore the Influence of: Build orientation Vertical Horizontal Support structure configuration Less Support Max Support MSC Software Confidential 21

18 Validation Examples

19 Validation Example MSC Software Confidential 23

20 Calibration of Inherent Strain by Simple Cantilever Build Step 1: Build cantilevers Cut Measure tip displacement MSC Software Confidential 24

21 Our Answer Metal AM Simulation Step 2: Automatic calibration Store in database Parameter Set 1 Parameter Set 2 Cutting in x Cutting in y AM Technical Training November 2nd 2016 simufact additive 1.0 MSC 25 Software MSC Confidential Software Confidential 25

22 Validation Example Simulation Actual Part MSC Software Confidential 26

23 Validation Example Parameter Set 1 NDES Cutting in x NDES NDES MSC Software Confidential 27

24 Validation Example Parameter Set 1 Distortions Point Simulation (mm) Experiment (mm) Cross Section Contour Distortion Simulation Experiment Scaled displacement = 10x MSC Software Confidential 28

25 Total Solution Manufacture Heat Treatment Cooling Remove supports MSC 29 Software MSC Confidential Software Confidential 29

26 Complex Manifold Renishaw MSC 30 Software MSC Confidential Software Confidential 30

27 Demonstration MSC 31 Software MSC Confidential Software Confidential 31

28 More Information MSC 32 Software MSC Confidential Software Confidential 32

29 Thank You

Validation of a Generic Metallurgical Phase Transformation Framework Applied to Additive Manufacturing Processes

Validation of a Generic Metallurgical Phase Transformation Framework Applied to Additive Manufacturing Processes Tyler London 1, Victor Oancea 2, and David Griffiths 1 1 TWI Ltd, Cambridge, United Kingdom