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Case Study: AM pressure valveBy: VTT Technical Research Centre of Finland Ltdand Nurmi Cylinders Oy
Initial Design ofNurmi Cylinders Oy
Traditional Valve• Straight and circular drillings• Auxiliary drillings that need to be plugged
afterwards• Risk of leakage
• Initial weight: 2,5kg
VTT Technical Research Center of Finlandinvestigated what would be the ideal configurationfor the part of their customer Nurmi Cylinders Oy
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Optimization: Altair OptiStruct
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Engineering Requirements• Safety factor
• yield stress: 1,8• Tensile strength: 2,7
• 300 bar pressure on all channels• Elongation: 11-20% acceptable• Side loads: 100kg• Bolt preload: 17,9 kN• Material should withstand marine environment
• Corrosive resistant material• First iteration H13 Tool steel• Final material: still under investigation
Loads put in Altair Hypermesh• Yellow: overall pressure in the channels• Blue: design space, material to be optimized• Pink: non design space
Topology Optimization workflow
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Hypermesh:• Meshing• Applying loads• Boundary conditions
Optistruct:• Topology optimization• Mass: 66% reduced
Optistruct:• First design analysis• Max stress area:
• 1004MPa• Hotspots due to
rough model
Topology Optimization workflow
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MeshingHypermesh
OptimizationOptistruct
1st SimulationOptistruct
Input for redesign3-maticSTL
3-maticSTL:Digital CAD software for AM
Mesh based design software• Import TO data from Optistruct• Cleanup rough mesh quality
• Smoothening, Booleans,…
• Recreate analytical shapes,• Surface segmentations, sharp edges, …
• CAD-like features• Fillets, extrusions, sketching, …
• And many more options6
Design Optimizations for AM
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2nd Design iteration:• No internal supports
• 45° with base plane• Elipsoide cross sections
1st Design iterationSupports needed to build internal
Channels
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MeshingHypermesh
OptimizationOptistruct
1st SimulationOptistruct
RemeshingSurface data
3-maticSTL
AnalysisHyperworks
ApprovedDue to the redesign tools, the maximal stress
regions were solved
Iterative design workflow
3-maticSTL:Digital CAD software for AM
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Applyloads
Optimization
Design for AM3-maticSTL
FEAApproved
AM preparationMagics RP
Finished
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Magics RP:Data preparation for SLM 125
Magics RP:• Positioning• Support generation• Defining scan profiles
Print drivers available in Magics RP
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Support needing surfacepreview
Teeth for easy removalPerforations for powder recuperation
Cones for strong anchorageon critical regions
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600g of mass comparedto the original 2,5kg(74% less)
improved flow because ofsmooth transitions betweenthe internal channels
The bionic design andsmall series were ideal forAM
No need for Auxiliarydrillings, less chanceof leakage
The time from optimizationto final design was greatlyreduced by workingimmediately on the TOdata with 3-maticSTL
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Materialise:Contact: [email protected]
With many thanks for sharing the case by:
VTT and Nurmi Cylinders Oy:Contact VTT: Erin Komi ([email protected])Contact Nurmi Cylinders Oy: Juha Elonen ([email protected])
Contact
