design methodologies for alm and lattice parts

Innovation Intelligence®

Design Methodologies for ALM and

Lattice parts

Blaise Cole – Application Engineer

October 8th 2015

Houston TX

http://altair-2.wistia.com/medias/l99z6z3fuc

Copyright © 2014 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

Overview

• Audience Questions

• Current ALM Activities

• ALM Overview

• Current Activities in Aerospace

• History of ALM in Aerospace

• Design for ALM Parts

• Efficient Workflow for ALM

• Future of Design/Analysis for ALM

• World Premier of Inspire 2016


General Conference Notes

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• #HeavyOnOptimization


Presentation Take-aways

• Do Additive, Do lots of it, and Do it now

• Current Design/Analysis workflow that is being used (successfully)


Audience Questions

• Does your company have a 3D printer

• Do you currently use ALM for anything?

• Conceptual designs

• Tooling

• My design team has a 3D printer, and I buy a lot of plastic for it, and all they make

are an army of minions.

• Do you have the capability to print metallic parts?

• Do you currently use ALM for any PRODUCTION parts?

• Why not???


Current Industry Issues with ALM

• Issue is NOT material properties

• Companies will do their own testing and qualification for materials anyways. Test pieces can be printed next to

the part so there is very good validation within the part

• Even though ALM is anisotropic process, using the smallest (most conservative) modulus will always provide

desired results

• Design rules

• Warpage for thin walls (length v. thickness)

• % factor that the part needs to be larger (easier to machine away, than add material)

• Overhang angle/support structures

• Build direction (weakest in the out-of-plane direction)

• Lattice

• Every printer is different, and every environment in each printer is different

• Determine how different printer settings affect the part

• Analysis of ALM parts

• Thermal/Residual stress

• Simulating at a “Slice Level”

• Simulating variations in the process• Laser Temp, % voids, % unmelted, etc…

• Aerospace – Hand certification becomes very challenging

• Qualifying good candidates for ALM

• Inspection and Certification


ALM Overview

• Only 2 main methods have proven for consistent, quality production

• FDM (Fused Deposition Modeling)

• Larger build volumes

• Faster

• Lots of Post-machining

• Additional design factors

• SLS (Selective Laser Sintering)

• Powder Bed

• Slower

• Much finer detail

• Control surface finish

http://eandt.theiet.org/news/2013/oct/images/640_3d-print-metal2.jpg

http://www.protocam.com/wp-content/uploads/2014/07/SLS-Laserform-A6.jpg


Current ALM Activities in Aerospace

• Plastic part count reduction

• Mostly seen in producing more complicated air duct systems in a single print

• Assembly line tools

• Generating on the fly solutions for assembly of parts to make an assembly job

easier and more consistent

• Creating cheap ‘one-use’ tools (tools for applying sealants and glues)

• Drill templates

• Initial Prototyping

• Tooling

• Using ALM for creating large forming tools with

minimum amount of material (topology optimization)

• Turbomachinery

• Fuel nozzles

• Part count reduction


History of ALM in Aerospace

• Print a current design for ALM

• Taking a part that was made conventionally (machined), and is now grown

• Adapt a current part for ALM

• Allows for a comparison between a current design and a new design

• Usually incorporate some optimization

• Show an increase in performance and decrease in weight

• Design a part for ALM

http://www.pddnet.com/article/2014/02/printing-3d-parts-aerospace-applicationshttp://blog.ponoko.com/wp-content/uploads/2011/05/Optimised-Hinge-vs-Original_x534.jpg


Design for ALM

• Topology Optimization

• Lattice

• Organic shapes

• Hollow parts

• Part Reduction


Issues with Designing for ALM

• Topology Optimization

• Lattice

• How do we deal with this type of part? Geometry? STL?

• Organic shapes

• How do I model this part (efficiently)

• Hollow parts

• Support structure? Removing supports?


Altair Current ALM Offering

• Use current CAD to create design space

• Inspire for Design/Interpretation

• Back to CAD to add parametric features

• HM/OS for Analysis/Lattice

• 3matic-STL for lattice interpretation and mesh cleanup

• Send out the STL file ~250GB

• No current offering for slicing/g-code creation

• Lots of free programs, file x1000 smaller


Traditional Engineering Workflow

Analysis Group

Pre PostSolve

Design Group

10x

Optimization

Production


Altair ALM Part Design Process:

DESIGN GROUP

HMOS HV

ANALYSIS GROUP

OSHM

PBSHV

PRODUCTION

TRADITIONAL ANALYSIS

HM OS HV

ANALYSIS GROUP

PBS

PRODUCTION ANALYSIS

LATTICE

SIZING


Future Needs for ALM Design & Analysis

• Seamless transition of data from each program that is being used

• Ability to categorize STL files and adapt them into the PLM system

• Integration of production analysis to help drive design

• Access to large CPU clusters to run slice models, then feed that data

into the design

• Access to print history data that can be used to help make better parts

• Standard printing configurations to test baselines and materials

• Train designers to think more organically, break away from traditional

designs

• New CAD program that can work on 3D parts


Final Thoughts/Summary/Recap

• Don’t be afraid to CTRL+P

• Data is the new forum in which we show confidence

• Use the inexperience of the newer generation to gain experience

• Trust in the software you use (and the user that is using it)