Simulate & Optimize the Additive Manufacturing Process with

Transcription

1 Driven by Driven by September 12, 2017 Simulate & Optimize the Additive Manufacturing Process with AlphaSTAR s GENOA 3DP Host: Scott Deutsch, America Makes AmericaMakes.us

2 Driven by Driven by Today s Webinar: Simulate & Optimize the Additive Manufacturing Process with AlphaSTAR s GENOA 3DP AlphaSTAR s GENOA 3DP test validated simulation tool can assess and predict shrinkage, warpage, and residual stress which are common to AM fabrication. Today s webinar will present: Today s Presenter: Cody Godines AlphaSTAR Corporation Simulation of the AM build Prediction of Mechanical Properties at Different Temperatures Prediction of Delamination and Other Manufacturing Anomalies Prediction of the Residual Strength of the Finished As-Built 3D-printed Part Subject to Service Loading. Assess Both Material and Process Parameter Sensitivities The resulting outcomes are reduced waste, reduced testing and, ultimately, an optimized AM part. 2 AmericaMakes.us

3 Agenda SIMULATE AND OPTIMIZE THE AM PROCESS WITH GENOA 3DP Background Challenges in Additive Manufacturing Material Modeling, Process Modeling, Service Load Simulations Why GENOA 3DP? Big Area Additive Manufacturing BAAM Fused Deposition Modeling FDM Simulation Process Demo 3DP Strati Car Demo Thermal Isogrid Model Demo ABS-CF13 Case Studies for Material Characterization of Unfilled, Filled Thermoplastic ABS CF ULTEM1010 Case Studies for AM Simulation Bosch Multi Hole Component (3DP Defect Detection) Multi Material Isogrid (Print Simulation and Service Load) Q & A 3

4 Thermoplastic Printing Problems Thermal Loading Induces Residual Stress and Delaminations Thermoplastic reinforced with short carbon fiber is placed while hot and not fully solidified. Layer by layer bead structure is produced. Temperature difference between beads result in asymmetric shrinkage and bending moments. Cohesive failure produces cracks Shear Stresses due to ΔTemperature Printing Process Thermography of Printing Δε=αΔT Cracks within beads Cracks between beads M M σ iz Cross section of two beads 4

5 Multi-Material AM Problems Material Model Should Consider Defects in As-Built Printed Parts Thermoplastic High Porosity, Sub-optimal Layer or Poly to Filler Interfacial Bonding Residual stress, delamination, wrinkles Defects, fiber waviness, agglomeration Multi Functional Gas and Process Induced Porosity Locked after Solidification Unfused Powder from Insufficient Melting Metal to PMC Printing Introduces New Dissimilar Material Region Joining Dissimilar Materials, Diffusion is ½ Layer Thickness, Debonding Results Cf & CNT+PEI Delamination & Porosity Gas/Process Porosity Metal to PMC Ti No-bond Ti Bonded iber reinforced PEI (left), carbon fiber and CNT reinforced PEI EI (right) that are designed to yield different and unique material Speed and power and other printing parameters need to be optimized 5

6 Why GENOA 3DP? Design AM components with Improvements in Mass, Cost, Schedule, and Performance Material Models Mechanical and fracture properties as a function of temperature Tensor orientations through thickness (fiber angle and thickness) Process Simulation of AM Part Design to Reduce Inherent As-Built Items: Residual Stresses Distortion Void Shape, Size, and Distribution Printing Pattern Anomalies (Bald Spots) Damage and Fracture Service Loading Simulation of As-Built Part to Assess Performance Identify Root Cause Problem Due to Manufacturing Process Parameters Determine scatter (uncertainty) and sensitivities to material/process/load 6

7 GENOA 3DP for AM Simulation 7

8 AM Simulation Flow Process Material Model Predicts Temperature Dependent Mechanical, Thermal and Fracture Properties: Composite Materials Consider Fiber Orientation, Constituent Properties, Curing Parameters, and Affect of Defects Powder Metal is Represented with Creep Diffusion, Void Growth, Surface Roughness, and Oxidation 8

9 Temperature ( C) AM Simulation Path to Prediction Material Characterization Coupon Test MCQ TEST Ply-Layup E (Msi) E (Msi) S (Ksi) S (Ksi) AM Build Delaminations Severe delaminations Validation Wall Model (Component) Thermal Layer 15 Layer 30 Layer 45 Layer 60 Layer 75 Layer 88 Analysis Time (s) Delamination Prediction Damage Contribution Thermal Prediction Dynamic Moving Grid 9

10 AM Computational Platform: Part 1 - Model Generation From G-Code to Multi-Scale Progressive Failure Bald spots visualization Layer time Simulation model Printer path lines. Material orientations from printer code Includes convection, conduction, radiation, temperature dependent cohesive failure and material models between and within the beads. Thermal or coupled structuralthermal solutions. 10

11 AM Computational Platform: Part 2 - Simulation Residual Stress Deformation Damage Mechanisms (Interlaminar Shear and Delamination) Multi-Scale Material Model 12 Hrs CPU, 24 Processors 11

12 Delamination Highlights Potential Delaminated Areas & Types Identified Delaminations Delaminations Delaminations Global visualization of the delaminations Delaminations Delaminations Driving direction Delaminations in the mid-console Local visualization of the delaminations (overexaturated displacements for the sake of visualization (x3)) 12

13 DEMO (VIDEO) GENOA 3DP Strati CAR BAAM 13

14 DEMO (VIDEO) THERMAL ISOGRID MODEL Ultem

15 DEMO (VIDEO) MCQ CHOPPED AS4-ABS 15

16 Material Characterization AS4-ABS Scatter and Orientation Ultem1010 Unfilled Filled Thermal + Chemical Shrinkage 16

17 Stress [MPa] Strength (MPa) Strength Orientation MCQ Chopped Capabilities: Independent of FEM Matrix or Ply Test Data Input Particle Shape & Aspect Ratio Fiber Waviness Manufacturing Defects Void Shape Agglomeration Interphase Test-A11 Test-A22 Test-A33 MCQ-A11 MCQ-A22 MCQ-A Normalized Thickness [z/h] Tensor Orientation Through Thickness Predicts Properties, Reduce Coupon Testing & Accounts for Scatter Chopped Mechanics Mechanical Properties (1) Stiffness (2) Strength (3) Conductivity Progressive Failure Material Uncertainty Fatigue Life Design Failure Envelope Fatigue SN Curve 100 Test-Flow Test-45-Deg Test-Cross-Flow MCQ-Flow MCQ-45-Deg MCQ-Cross-Flow Strain [mm/mm] 10 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08 1.E+09 Cycles Cycles to Failure Test-0-Degree Test-90-Degree Test-45-Degree MCQ-0-Degree MCQ-90-Degree MCQ-45-Degree 17

18 Tensile Strength (MPa) Tensile Modulus (GPa) AS4-ABS: Material Property and Scatter in FDM Predict Strength, Modulus, Scatter & Compare with Test Input AS4 and ABS properties Fiber Length and Fiber Weight Fraction Void Volume Fraction Interface Shear Strength 2 nd Order Orientation Tensor Components for ABS/CF Composite Uncertainty Analysis used Fiber Length as Random Variables (Std Dev) FDM-Printed Tensile Modulus Test E11 MCQ-Chopped-Voids Fiber Loading (wt %) FDM-Printed Tensile Strength 0% 10% 20% 30% Test S11 MCQ-Chopped-Voids Higher Weight Percent Introduces More Defects Fiber Loading (wt %) 18

19 Orientation Tensor Components Orientation Tensor Components Orientation Tensor Components Orientation Tensor Components AS4-ABS: Orientation Tensor in FDM Tensor Orientation Prediction Through Thickness Verified with Test % wt 20% 10% wt of Fiber 20% wt of Fiber A11 (MCQ-Chopped) A11 (Test) A22 (MCQ-Chopped) A22 (Test) A11 (MCQ-Chopped) A11 (Test) A22 (MCQ-Chopped) A22 (Test) Normalized Thickness Average Paper Physics Normalized Thickness Laminate Analogy % wt 40% 30% wt of Fiber 40% wt of Fiber A11 (MCQ-Chopped) A11 (Test) A22 (MCQ-Chopped) A22 (Test) A11 (MCQ-Chopped) A11 (Test) A22 (MCQ-Chopped) A22 (Test) Normalized Thickness Normalized Thickness 19

20 Un-Filled: ULTEM 1010 Material Nano-Mechanics Implementation of Cylindrical Air Particles Input Air ULTEM 1010 Output Modulus Strength Air as Cylindrical Voids Ply Stress-Strain Curve Test vs. MCQ 22% of Air Particle Considered Strength and Strain based failure criteria is considered XZ-Test XZ-MCQ % Diff ZX-Test ZX-MCQ % Diff Tensile Modulus Tensile Strength Compressive Strength

21 Filled ULTEM 1010 Composite Micro-Mechanics Prediction of 3D Printed Filled ULTEM 1010 Properties Input Calibrated Filler Properties Calibrated Matrix Properties Output: Test vs. MCQ SS Curves 0 o 90 o Calibrated Filler Stress-Strain Curve Calibrated Matrix Stress-Strain Curve ±45 o 21

22 ULTEM 1010: Material Allowables (B-Basis) +/- 45 Deg Printed Defects and Matrix Properties turned into Design Variables COV of UTS Validated B Basis Predicted Test Measurement Test MCQ %Diff UTS (ksi) Mean % UTS (ksi) Cov % UTS (ksi) CMH-17 B Basis

23 ULTEM 1010: Material Allowables (B-Basis) CDF of UTS Ultem 1010 Used for B Basis and Reliability Determination Sensitivity Determines Importance and Direction of Optimal Performance 23

24 Stress (psi) Modulus (psi) Poisson s Modulus ratio (psi) Filled ULTEM 1010: Thermal Dependent Material Properties Multifactor Technique to Calculate Temperature Dependent Modulus, Poisson Ratio and Strength & Failure Type Temperature Dependent Mechanical Properties Temperature vs. Modulus Temperature (F) Temperature vs. Poisson Ratio Temperature (F) 70 o F Stress-Strain Curve 70 F 200 F 300 F 390 F Strain 24

25 Case Study BOSCH Test Article 25

26 Part 1: AM Material Modeling Inputs: BASF Terluran Datasheet Grade 958 I Non-linearity of ABS from Fig. 6 of article Assumptions: Void in 3D printed part ~22% Void is cylindrical with aspect ratio 4 Non-linearity of ABS Modulus XZ (11) and ZX (22-33) Strength XZ and ZX ABS 958 I Mechanical Props 26

27 Part 2: Printing Process Simulation Printer Path line/mesh Layer) GENOA 3DP Void Visualization Material Orientation for Top Layer Defects Detected With GENOA 3DP - Void (shape, size, distribution) - Stiffness Degradation - Fatigue Life Reduction 27

28 Part 3: Service Loading Predicted Part Service Loading (Static) Displacement Control Max stress-based failure criteria No residual stress from 3D printing Post Fracture Degradation Factor of 15% Damage Initiation Damage Propagation 28

29 Part 3: Service Loading Simulation 3 Assess Type of Damages and Their Locations Damage Initiation (S11T) Schematic of Damage Occurrence 1 3 Propagations Just Showing Delamination Damage 29

30 Case Study Isogrid Structure Print and Service Load Simulation 30

31 Isogrid FDM Simulation Performed Temperature ( C) 345 C is Scale Max Thermal History Of Bottom Node Near Wall Fluctuation as new material laid down FDM is a Dynamic Moving Grid Approach Layer #25 Printed Filled Isogrid 31

32 Isogrid Post Print Residual Stress and Deformation Residual Stresses Deformation 32

33 Isogrid Post Print Damages 33

34 3 Point Bend Test vs. Simulation of Unfilled 1010 Test of Isogrid Load Displacement Curve Sensitivities and CDF of Peak Load Due to: 1. Chamber Temperature 2. Fiber Strength in Tension 3. Fiber Strength in Compression and 4. Matrix Strength in Tension 5. Matrix Strength in Compression 6. Print Speed 7. Print Pattern 34

35 Damage Mechanisms During Loading Overall Damage Foot Print, and Type Contributing Failure Type Fiber (S11T) Matrix (S22T) Shear (S12S) Delamination (S33T) Delamination (S33C) 35

36 Conclusions GENOA 3DP Can Simulate the Entire AM Process: Material: Unfilled/Filled, Temperature Dependent, Effect of Defects, Validated Database Print Process Simulation: Mesh & Model Generation > Dynamic Moving Grid > Heat Affected Zone > Global to Local Modeling Residual Stresses, Deformation, and Delaminations Predicted Location of Damage and Fracture Thermal Profile Validation Coupled Structural-Thermal Solution Improve Manufacturing Process: Adjust Design Parameters Printing Speed, Intrusion Distance, Material Temperature, Ambient Temperature, Material Type, Inclusion Orientation, Aspect Ratio (i.e. fiber length) 36

37 Future Release Plans Metal Powder - Q4 2017: SLS (Selective Laser Sintering) DMLS (Direct Metal Laser Sintering) (e.g. EOS) DLD (Direct Laser Deposition) / EBM (Electron Beam Melting) (e.g. ARCAM) Ceramic Q1 2018: Binder Jet Printing 37

38 Driven by Driven by This concludes today s TRX Webinar: Simulate & Optimize the Additive Manufacturing Process with AlphaSTAR s GENOA 3DP QUESTIONS? Please type your questions into the Q&A section of the Webex screen and we will do our best to answer them all If you have additional questions that require a more in-depth conversation, please contact AlphaSTAR directly via at: info@alphastarcorp.com 38 AmericaMakes.us