Design for Additive Manufacturing Julien Magnien

Transcription

1 Design for Additive Manufacturing Julien Magnien

2 Sirris Driving industry by technology INCREASE THE COMPETITIVENESS OF COMPANIES THROUGH TECHNOLOGICAL INNOVATIONS Expertises Who are we? Collective centre of the technology industry Industry owned & approved 140 technological experts Serving 5000 clients, 80% SME

3 MOST COMPLETE INSTALLED AM BASE IN EUROPE TEAM OF 20 INDEPENDENT EXPERTS, 25+ YEARS OF EXPERIENCE METALS, POLYMERS & CERAMICS MORE THAN 10 AM TECHNOLOGIES IN-HOUSE

4 ICT & design tools SIRRIS VALUE CHAIN Materials Process Post- Process Leading-edge applications & components

5 DRIVERS FOR ADDITIVE MANUFACTURING Material efficiency flow optimalisation integration of functions massa customisation zero lead-time automated manufacturing

6 material efficiency What If we can use material, only there where needed DRIVERS FOR ADDITIVE MANUFACTURING

7 Original (7) parts Design volume Optimised structure 530g 7 parts 3 materials 392g 2 parts 1 material

8

9 flow optimisation What If we can create complex channels inside our products DRIVERS FOR ADDITIVE MANUFACTURING

10 HEAT EXCHANGER HYDROVISION cm³ vs 244 cm³ 19.2 kg vs 1,2 kg 210 mm vs 85 mm 750 vs (112 parts) Pressure drops -90%

11 CONFORMAL COOLING HYDROVISION

12

13 DIESEL FRONT PLATE CONVENTIONAL OPTIMIZED 40% weight reduction + optimized flow

14 integration of functions What If we can add multiple functionalities in one part DRIVERS FOR ADDITIVE MANUFACTURING

15 FUEL NOZZLE GE - LEAP ENGINE 25% lighter 18 parts into 1 5 times more efficiënt by using integrated cooling channels

16 COLLIMATOR CSL 13 parts vs 2 parts Integrated cooling channels Tollerances ok

17

18 mass customization What If we can start a seriesproduction where each part is slightly different DRIVERS FOR ADDITIVE MANUFACTURING

19 HEARING aids PHONAK / MATERIALISE phonak invisible 100% custom made > parts

20 THINGS TO CONSIDER LIMITATIES Available materials Accuracy of the technology Price of industrial machines Certification of materials and processes Surface finish (supports, post-processing) #parts>< dimensions>< material

21 HOW TO DESIGN FOR AM? EMPATHIZE IDEATE DEFINE PROTOTYPE TEST & ADAPT

22 HOW TO DESIGN FOR AM? EMPATHIZE DEFINE MAIN PROBLEMS DRIVERS salt vs Alluminium 50 parts / year material material efficiency low volume ADDED VALUE size # parts used materials thermal wire improve installation

23 HOW TO DESIGN FOR AM? IDEATE

24 HOW TO DESIGN FOR AM? IDEATE PROTOTYPE

25 HOW TO DESIGN FOR AM? TEST & ADAPT

26 HOW TO DESIGN FOR AM? Original design 8 parts complex assembly alu, inox, steel, rubber corrosion Optimised design 3 parts easy assembly titanium & rubber corrosion proof More expensive - premium market

27 Julien MAGNIEN, Additive Manufacturing

28

29 Developments in Topology Optimization for Additive Manufacturing Matthijs Langelaar Structural Optimization & Mechanics Delft University of Technology

30 Outline Introduction to topology optimization Link with AM: potential & challenges Current developments Conclusions

31 Topology optimization: generating the best material distribution What shape to use? Where to place material? bracket Design domain Topology optimization result post-processed final design

32 Topology optimization process 1. Define problem: - Objective, constraints - Domain, boundary conditions - Loadcases 2. Discretize and parameterize material distribution Maximize stiffness Use only 50% material i 3. Optimize material distribution for best performance 4. Evaluate / fine-tune result (postprocessing, shape optimization) Load

33 Topology optimization loop New Values of the density variables Component analysis (FEA) New Values of the objective and constraints New Gradient information (design sensitivity) Optimization algorithm

34 Topology optimization characteristics Strengths Little designer input needed High potential to find radically new designs Systematic way to solve complex design problems Challenges Optimized geometries complex: conventional fabrication difficult Post-processing often needed Link to other CAD tools underdeveloped

35

36 Uniform temperature increase

37 Topology optimization & 3D printing synergy 3D printing enables realization of full benefits of topology optimization Complexity for free Much less re-engineering needed Optimal performance remains intact

38 Topology optimization & 3D printing synergy Topology optimization enables realization of full benefits of 3D printing Generate designs that fully exploit 3D printing potential Create tailor-made optimized parts Reduce design iterations, improve time-to-market

39 Status: maturing design technology Commercial software available Successfully adopted in industry Developments towards more complex design problems Shift from conceptual design to final design Demand for print-ready designs

40 Print-ready topology optimization: Challenges AM design constraints Feature size Calignano 2014 Overhang angle Minimize costs due to supports Suitable design Best build orientation Facilitate easy removal Control local material quality Process modeling Microstructure prediction

41 Overhang angle limitation: Post-processing of designs Leary et al. 2014

42 Support structures vs. Post-processing Leary et al Part volume 48 cm 3 Support 42 cm 3 Build time 5.7 h Part volume 55 cm 3 Support 0 cm 3 Build time 2.6 h

43 Overhang angle limitation: Adding permanent lattice structures Lattice acts as support structure Remains functional part of component Challenge: quality control

44 Vision: include overhang constraints in optimization Mesh-based Boundary-based Reuben Serphos Emiel van der Ven

45 Mesh-based overhang constraints Overhang detection With constraint: overhang-free design Effective in removing overhang Costly additional computations Limited to 45 overhang angle

46 Boundary-based overhang constraints Reference 45 angle limit 30 angle limit Effective in enforcing boundary orientation limits Applies to any overhang angle Generates free-standing points

47 Status Partial success in enforcing overhang constraints, further development needed Next challenges: Including small overhanging sections Extending to 3D Including build orientation End goal: Including all relevant process information

48 Topology optimization Values of the density variables Component analysis (FEA) Values of the objective and constraints Optimization algorithm Gradient information

49 Topology optimization for print-ready designs Build information Printing process simulation Component analysis (FEA) Values of the objective and constraints Gradient information Optimization algorithm

50 Process modeling Khairallah et al, 2014 Marius Knol, Can Ayas

51 Conclusions Synergy between topology optimization & AM Specific constraints required Progress on overhang constraints Ultimately, integration of process simulation Development of AM process models for design: key aspect

52 Developments in Topology Optimization for Additive Manufacturing Matthijs Langelaar Structural Optimization & Mechanics Delft University of Technology

53

54 LET ADDITIVE MANUFACTURING INSPIRE YOU New Thinking Unmatched Performance From pioneering high-end production to a global vision Raph Alink Key-accountmanager 3DS LayerWise raph.alink@3dsystems.com NYSE:DDD

55 Increase your added value through advantages of Metal Additive Manufacturing 3DS-LayerWise offers its technological expertise realized by being technology developer as well as technology user

56 Additive Manufacturing AM Polymers Metals Ceramics Glass Powder Bed Technology EBM Powder Deposition Technology Laser Cladding DMP Selective Laser Melting (SLM), Laser Beam Melting (LBM), Direct Metal Printing (DMP)

57 Direct Metal Printing Evolution Research Material Parts Quality Productivity 100% prototyping 4 materials 90 x 90 x 90 mm Worlds First 3D Printing of Titanium 90% Volume Manufacturing 18 materials 280 x 280 x 440 mm Leading DMP manufacturer

58 Materials Dental Medical Industrial Aero 316L Stainless steel SS 17-4 SS 15-5 Tool steel Maraging X3NiCoMoTi Ti commercially pure Titanium Ti commercially pure Ti6Al4V ELI Ti6Al4V CoCrMo Super alloy CoCrWMo Inconel 718 Inconel 600 Aluminium Exotics AlSi10mg Tantalum Tungsten Several materials under development 3D Systems has capabilities to accommodate new materials within a typical timeframe of 3 months

59 SLM Production Basic principle: 3D part produced as a stack of interconnected 2D- layers ( Layer-Wise )

60 DMP Technology Directly from 3D CAD Layer-wise production 3D components by successive connection of thin 2D layers

61 Basic Design Rules for DMP Free form design Build direction

62 Industrial Drivers & Applications

63 Industrial challenge for 3D printing same materials same characteristics? What is the added value? = Improved Performance, Complex functionality Lower TCO

64 Industrial Markets AM offers: Functional integration: Simplified assembly Weight reduction Complex shapes Quick turn around Last minute design changes possible Semicon Precision Mechanics Oil & Gas Food & Pharma Aerospace & Space (Petro-)chemical

65 Design for Function Wire Guides Thermal Isolation Fit Weight Turbulence Flow Optimization: 90% reduction in mechanical interference forces Original (PEEK)

66 Design for Function Functional integration (Monolithic part) Integrated Cooling channels Improved performance and lifespan Quartz bulb burners with integrated cooling channels (Courtesy of Havells Sylvania)

67 10 mm Design for Function No Tooling costs Reduced delivery time Significant cost reduction

68 10mm Miniaturization

69 Important advantage of AM: Complexity comes Free of Charge With conventional production methods, complexity increases cost with AM, Complexity does not increase cost Radnabe aus Titan für einen Formula Student Rennwagen. Team: Racetech Racing Team TU Bergakademie Freiberg e.v.

70 Conclusions Is AM useable for Industrial High-end applications? 1. Metal AM is here to stay Technology development Specific uses for AM Processes 2. Quality is Key Material Validation 3. Specialized technology Purpose-built AM production systems Automation & process control 4. Partnership Application expertise Technology expertise Production expertise

71 3DS LayerWise Grauwmeer Leuven Belgium tel: fax: THANK YOU