additive manufacturing - gpdis · title: microsoft powerpoint -...
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BOEING is a trademark of Boeing Management CompanyCopyright © 2017 Boeing. All rights reserved.
Copyright © 2017 Northrop Grumman Corporation. All rights reserved.GPDIS_2017.ppt | 1
Additive Manufacturing
From Trial and Error to a Standard Industrial Process
Global Product Data Interoperability Summit | 2017
BOEING is a trademark of Boeing Management CompanyCopyright © 2017 Boeing. All rights reserved.
Copyright © 2017 Northrop Grumman Corporation. All rights reserved.GPDIS_2017.ppt | 2
Topics
• Introduction
• Process Simulation of AM– Metals– Polymers and Composites
• Conclusion
Global Product Data Interoperability Summit | 2017
BOEING is a trademark of Boeing Management CompanyCopyright © 2017 Boeing. All rights reserved.
Copyright © 2017 Northrop Grumman Corporation. All rights reserved.GPDIS_2017.ppt | 3
Additive Manufacturing (AM) opens up amazing possibilities
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It also comes with its own, unique challenges
First Time Right
OptimalSupport
Structure
ReducedTry-Out Shorter
Print Time
EfficientSerial
Production
Optimized Shape
Minimize material Usage
Correct Microstructur
e Part Performance
Porosity
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Main challenges
• Distortion– Part out of tolerances– Collision with powder scraper
• Residual Stresses– Part of support failure
• Quality– Porosity– Microstructure
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Additive Manufacturing (AM) Process
Design Build Inspect
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With manufacturing simulation
Design Manufacturing Simulation Build Inspect
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AM Process Simulation
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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
InformationExchange
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Macro scale
IMPLEMENTATION RESULTS
BENEFIT
• Part distortion• Residual stress
• Extremely fast• Simple calibration CPU Time
5 minutes
• Voxel technique
• Inherent strain
• Layer based
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Voxel technique with solid fraction
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Inherent strain
Comprise– Plastic strains– Thermal strains– Creep strains– Phase transformation
strains
Reflect– Material– Manufacturing
parameters– (Individual) machine
Are orthotropic by nature
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Calibration of inherent strain by simple cantilever build
Step 1: Build cantilevers Cut Measure tip displacement
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Calibration of inherent strain by simple cantilever build
Step 2: Automatic calibration Store in database
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Once calibrated, run simulations on actual parts
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Validation Examples
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Validation example
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Validation example
Simulation Actual Part
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Validation example
Cutting in x
Parameter Set 1
NDES
NDES
NDES
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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
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Validation example
Parameter Set 1
Sinterline® powder (Glass beads reinforced polyamide)
SimulationExperiment
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Validation example
Stratasys – Composite Tooling
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Virtually explore the influence of:
Parameter Set 1 Parameter Set 2
• Cutting direction & supports removal sequence
• Manufacturing parameters & materials
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Virtually explore the influence of:
• Support structure configuration
Vertical Horizontal
Less Support Max Support
• Build orientation
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Virtually explore the influence of:
• Process chain AM Build Cut from PlateHeat Treatment
Remove Supports HIPCooling
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Virtually explore the influence of:
• Optimal compensated shape
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Polymers Example
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Consideration of polymer partsA
dditi
ve L
ayer
M
anuf
actu
ring
Add
itive
Lay
er
Man
ufac
turin
g
FFF/SLSFFF/SLS
Material Engineering
Material Engineering
MechanicalMechanical
ThermalThermal
ElectricElectric
Process SimulationProcess
Simulation
WarpageWarpage
Residual StressResidual Stress
PorosityPorosity
Part Performance
Part Performance
StiffnessStiffness
FailureFailurePrint DirectionPrint Direction
ReinforcementReinforcement
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Sinterline® plenum chamber; Powder Bed Fusion (SLS)
• Plenum is part of the Polimotor project (all plastics engine)• Long-term goals:
• Introducing plastic parts in future automotive engines• Highlighting trailblazing polymer technologies and their potential
• Challenge: the additively manufactured plenum must demonstrated that:• It can withstand the working loads• It can perform with same reliability as its injection molded counterpart
Polimotor 23D printed plenum
chamber
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Material characterization with nonlinear micro-mechanics
E Σ
Local phase behavior
Global behavior
Localization Averaging
εr σr
EHx rrr :)(
rrr c :
:)( rcc
Finite ElementMean Field
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Sinterline® material characterization
Stress-Strain curves and Failure dependent on printing orientation
0
50
100
0 1 2 3
True
Stre
ss (
MP
a )
TrueStrain (%)
Tensile test (RH0), depending of printing orientation,
compare to Digimat model
0°
15°
30°
45°
60°
75°
90°
Digimat model
020406080
100120140160
0 5 10 15 20
True
Stre
ss (
MP
a)
True Strain (%)
Compressive tests (RH0) depending on samples printing orientation, compare to
Digimat model
57.764.5 70.3
73.1
75.2
77.5
82.2
90
80
70
60
50
40
30
20
10
00 10 20 30 40 50 60 70 80 90
90° 75°
60°
45°
30°
15°
0°
57.759.5 64.872.2 78.6
81.6
82.2
Experimental
Digimat modelSamples printed at:
Failure
0°
90°
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Simulate AM build process
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Performance analysis
Pressure at failure for different build orientations• Build in width direction 12.8 bars• Build in height direction 12.0 bars• Build in length direction 8.1 bars• Build in angled orientation 9.1 bars
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Experimental testing
• Method• Pressure increase by steps up to 6 bars positive air pressure inside the plenum• Pressure release to ambient pressure after 1 hour at 100 degrees C
• Conclusion• No burst of the part during test validation of part strength• Test successful
Pressure sensor
Experimental pressure profile Experimental set up
Air inlet
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Copyright © 2017 Northrop Grumman Corporation. All rights reserved.GPDIS_2017.ppt | 35
Metal AM Simulation - Prediction of microstructure
Transient simulation with microstructure in cooperation with MRL
AM ICME platform for data analytics, material modeling, and FEM simulations
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Conclusion
• You can design amazing structures – simulation is a must to reliably print them
• Simulation is required for:– the whole process (build, cut, heat-treat),– the complete chain (material, process, performance)– At different scales (macro, meso, micro)
• New simulation tools are available and are advancing rapidly