Additive Manufacturing: FEA Based Design and Optimization with Abaqus, ANSYS and MSC Nastran
Additive manufacturing, also known as 3D printing, is a method of manufacturing parts typically from powder or wire using a layer by layer approach. Interest in metal based additive manufacturing processes has taken off in the past few years. The three-major metal additive manufacturing processes in use today are powder bed fusion (PBF), directed energy deposition (DED) and binder jetting processes.
ESimLab Engineering Team propose special simulation tools for each of these processes. With additive manufacturing, the design is not constrained by traditional manufacturing requirements. Nonparametric optimization with technologies can be used to produce functional designs with the least amount of material. Additive manufacturing simulations are key in assessing a finished part’s quality. The physics behind the manufacturing process can be accurately recreated in software platforms, and enabling end to end digitalization and so on, factors which will be crucial in the service life of a part.
ESimLab’s Engineering team with efficient utilizing real world transient simulation, with FEA Solvers such as Abaqus, Ansys, LS-dyna, Nastran and MSC Marc and clear knowledge about the assumptions and simplifications that must be made to get results with required accuracy.
Considering complexity and needs to have new procedure and constitutive equation, we must try to develop new FEA and CFD based software to overcome engineering challenges.
FEA and CFD based Programming needs experience and deep knowledge in both Solid or fluid mechanics and programming language such as Matlab, Fortran, C++ and Python.
We use subroutine’s with programming languages such as Fortan, C and Python in CFD and FEA sofware such as Abaqus, Ansys, Fluent and Star-ccm+ to add new capability and Constitutive equation.
ESimLab use Mathematical Methods and Models for Engineering Simulation. We, focuses on numerical modelling and algorithms development for the solution of challenging problems in several engineering sectors specialized in the development of software for the numerical discretization of partial differential equations, linear algebra, optimization, data analysis, High Performance Computing for several engineering applications.
Additive Manufacturing Processes and Methods : Directed Energy Deposition, Material Extrusion, Sheet Lamination, Photo Polymerization, Material Jetting, Powder Bed, Binder Jetting
Optimizing the design parameters for additive manufacturing
ESimLab Engineering team simulates the printing process to identify manufacturing issues and optimize printing parameters for productivity and final part performance, for instance by minimizing part warpage and residual stresses as a function of the material and process parameters. Our Simulation Based Design and Optimization enables the prediction of the as-manufactured part performance, therefore allowing precise understanding of final part mechanical properties and helping with optimization of performance for lightweighting and covers a wide range of Industries like Automotive, Aerospace, Oil and gas, marine, medical devices, heavy engineering and Industrial and consumer appliances.
FEA Based Simulation enable our engineering team to gain insight into the microscale meltpool phenomena by performing full factorial studies with various process parameters for determine the best process parameters for any machine/material combination, and ensures the achievement of the highest integrity parts, as well as the expected microstructure and physical properties:
• Optimize and fine-tune their machine and material parameters.
• Develop new metal powders and metal AM (Additive Manufacturing ) materials and material specifications.
• Determine optimum machine/material parameters.
• Control microstructure and material properties.
• Manufacture using new metal powders faster and more efficiently.
• Reduce the number of experiments needed to qualify components.
• Mitigate risk while accelerating innovation.
• Analyze Porosity and Meltpools.
• Thermal history and microstructure information.
• Determines the percentage of porosity in a part due to lack of fusion.
Metal AM (Additive Manufacturing) FEA Simulation and Optimization
Our FEA Based solution for Metal Additive Manufacturing, puts its focus on build simulation and subsequent steps including heat treatment, cutting the base plate, removing supports, and Hot Isostatic Pressing (HIP). The process simulation solution addresses both manufacturers and researchers and their needs.
• Shorten your training process dramatically
• Investigate more variable prior to the production
• Shorten time-to-market
• Reduce material and energy consumption costs
The solution’s functionality helps you to answer urgent challenges in the build process while providing higher efficiency by automation and assistant functionality:
• Identify the best build orientation
• Determine and compensate final part distortionGenerate and optimize support structures
• Process window pre-scanning tool
• Powder coating
• Melt pool shape and dimensions
• Consolidated material porosity
• Surface roughness
• Thermal history as a function of deposition strategy
• Residual stresses
• Distortion during build process and after release
• Identify manufacturing issues such as cracks, layer offsets, recoater contact
• Predict the influence of several components in the build space
• Identify cold and hot spots due to thermal/thermo-mechanical simulation
• Examine conditions of highly elevated temperatures and pressures – HIP proces
Additive manufacturing: Lattice Structures
Additive manufacturing offers the ability to build lightweight components designed through topology optimization, incorporating lattice structures to provide conformal cooling. Lattices are repeated arrangements of unit cells. The numerous shapes and sizes available for unit cells have led to a breakthrough in the production of more robust lightweight materials and structures.
In the modern manufacturing world, lattice structures are being used for internal support, reducing the amount of material or improving the strength-to-weight ratio. Medical implants, automotive and aerospace and defense components are a few major applications which have directly benefitted from lattice structures. To further improve the efficiency of these lattice structures, they can be optimized for the required in-service loading conditions.
Laser Welding and Additive Manufacturing
Superior productivity and speed, coupled with low heat input are resulting in laser welding processes replacing the more conventional welding methods. In addition, the laser technology has further enabled metal additive manufacturing processes for both powder bed based and metal deposition. We look at how process parameter optimization and relevant physical models play an important role in predicting porosity, surface finish and the subsequent microstructure evolution in welding and additive manufacturing processes.
Topology, Shape and Bead Optimization for Additive Manufacturing
For additive manufacturing, Optimized structure is the most important thing, and there is big effort to include all aspect of real-world physics to simulation for accurately simulate the process. In the early stages of design, FEA based Simulation and Optimization can reveal various design options to reduce weight and materials, while also maintaining and improving the rigidity and durability of the product. In the late stages of design, when improvements and major changes are limited, we can investigate stress points in conjunction with stress reducing materials to find solutions without making geometrical changes.
Through the variety of simulation tools available, you can save weight and ensure the highest product quality. There is no need to guess or test multiple times– with simulation you can be sure your product will perform as it is supposed to. ESimLab’s Simulation Consultant allow you to save materials while decreasing weight and ensure you have the highest product quality.
ESimLab engineers uses topology optimization in conceptual design to create lighter but stiffer parts and structures. we offer the ability to make designs ready-to-manufacture meaning that fewer prototypes are built, and fewer physical tests are needed, saving time and money. Our engineers can produce strong and lightweight parts through material reduction strategies. The final topology investigated to evaluate the fatigue and durability criteria by our engineers.
With shape optimization, our engineers can not only optimize the shape of your designs during initial design, but also go back and improve old designs. These structural optimizations modify surface geometries to suggest the best shapes for structural and performance needs.
Through bead optimization our engineers can improve the static and dynamic properties of shell structures.
Real world Simulation: Combination of experience and advanced analysis tools
Calling upon our wide base of in-house capabilities covering strategic and technical consulting, engineering, manufacturing ( Casting, Forming and Welding) and analytical software development – we offer each of our clients the individual level of support they are looking for, providing transparency, time savings and cost efficiencies.
ESimLab engineers participate in method development, advanced simulation work, software training and support. Over experiences in engineering consulting and design development, enables ESimLab’s engineering team to display strong/enormous client focus and engineering experience. The ESimLab team supports engineering communities to leverage CFD-FEA simulation softwares and methodologies. It leads to the creation of tailored solutions, aligned with the overall product development process of ESimLab clients.
CAE Simulation: CFD, FEA, System Modeling, 1D-3D coupling
Integrated expertise covering every Equipment component analysis. From concept through to manufacture and product launch, and for new designs or Equipment modifications, we provide engineering simulation expertise across projects of all sizes. Simulation has become a key enabling factor in the development of highly competitive and advanced Equipment systems. CAE methods play a vital role in defining new Equipment concepts.