Design for Additive Manufacturing - Amazon S3€¦ · Stl. / stp. Stl. Build file Betatype Engine Arch. Build file (MTT) + Betatype plugin) Conventional Engine Rhino (intra-lattice

Design for Additive Manufacturing Betatype Capability Demonstration

June 2016

Contents

1 Manual & Automatic Optimisation

2 Hardware Used

3 Lattice Generation

4-5 Component Validation Random Lattice Structure

6 Unitform Lattice Converted to stl.

7 File Fixing – Magics

8 File Fixing – Other Software

9 Build Processer – Renishaw

10 Simulated Build – Renishaw

11 Engine Route

12 Build – Renishaw AM250 (Actual)

13-14 Timings and Summary

15 Within – Lattice Generation

16 File Fixing – Magics

17 File Fixing – Other Software

18 Build Processer & Simulated Build Time – Renishaw

19 Timings and Summary

20 Manual & Automatic Optimisation

21 Overview

This project received MTC SME Reach Support. For more information, contact: [email protected]

mailto:handbook%40the-mtc.org%20?subject=MTC%20SME%20Reach%20Support%20%E2%80%93%20More%20information%20requested

+ Betatype plugin)

Conventional

Engine

Rhino (intra-lattice

Stl. fixer Build Processor

FE validation

AM MachineBuild

DFX/IGES

Stl. Stl. Build file

BetatypeEngine

Arch.Build file(MTT)

Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


Manual Optimisation

Automatic Optimisation

1

Hardware Used

HP ZBookProcessor: 4 x Intel Core i7 CPU 2.50GHzRAM: 24GB

2

Unit cell topology X

Unit cell size 2mm

Beam thickness 0.15-0.75mm

Grading Linear through z

Beam count ~120,000

File size 39mb

Time 10mins

Unit cell topology N/A

Unit cell size N/A



Beam count

File size 37mb

Time 10mins

Lattice Generation

• Lattice structures produced using Rhino / grasshopper / intra-lattice

• Uniform and random lattice structures produced

• Both files taken forward for simulations

• Only uniform structure taken forward for assessment as an stl

Uniform Lattice Structure Random Lattice Structure

+ Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


10mins

3

• Component validation carried out in COMSOL

• Lattice structure exported from Rhino as a .dxf file

• Lattice modelled as beam elements with associated thicknesses (grading through z, 0.15-0.75mm)

• Skin modelled as 2D elements with associated thickness

• Skin-lattice connections modelled as fused joints

Component Validation Random Lattice Structure + Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


10mins

170mins

4

Component Validation Random Lattice Structure + Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


10mins

170mins

5

Uniform Lattice Converted to stl.


Unit cell size 2mm



Beam count ~120,000

Triangle count 9,525,963

File size 465mb

Time 15mins

+ Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


25mins

170mins

6


File size 465mb


File size 439mb 135 mins

File Fixing – Magics + Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


25mins

170mins

135mins

7

File Fixing – Other Software

Netfabb professional

Blue screen of death

Limitstate:FIX

Programme crash

+ Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


25mins

170mins

8

Processing failure – Open edges (errors seen in Magics)

Build Processer – Renishaw + Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


25mins

170mins

135mins

9

Simulated Build – Renishaw

• In reality, a build would not be able to take place given the failure to create a slice file

• For the purpose of comparison, a slice file has been created from wireframe geometry and a build (using standard scan parameters) has been simulated

• Both periodic and randomised lattice structures were taken forward for build simulation

Results

High Density Randomised Lattice

Single blade = 2,285 mins15 blade array = 22,727 mins

Periodic 2mm Lattice


+ Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


25mins

170mins

135mins 135mins

1,519mins

10

Engine Route

Action Software TimeLattice Slicing Engine 202 seconds

Solid Slicing Netfabb 6.4 180 seconds

Path Optimisaiton Engine 84 seconds

MTT Generation Engine 501 seconds

TOTAL 967 seconds 16.12 mins

+ Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


25mins

170mins

16mins

11

Build – Renishaw AM250 (Actual)

High density Randomised lattice (simulated)

Single blade = 1,148 mins 15 blade array = 5,712 mins

2mm Uniform Unit Cell (simulated)


+ Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


25mins

170mins

16mins

12

Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


+ Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Timings and Summary

No build processor and AM simulated build times available as route is not possible

STL.workflow EngineWorkflow

CAD geometry 25 10

FE validation 170 170

Stl. Fixer 135* N/A

Build processor FAIL N/A

Betatype engine N/A 16 330 196

DesignWorkflowTimings

13

Timings and Summary

Build Comparisons

Single Turbine Blade

Array of 15 Turbine Blades

Design Number of Simulated Build Build speed Dosing Estimated Estimated Simulated Build Speed Designation Elements Time (mins) improvement Percentage Dosing Marking Build Improvement (x) (%) Time (mins) Time (mins) Time (mins) (x)

Betatype Periodic 2mm Lattice 121285 1061 1.4 77.00% 817 244 4477 2.0

Current Periodic 2mm lattice 1159 64.80 984 535 9005

Betatype High Density 679982 1148 2.0 71.60% 822 326 5712 4.0 Randomised Lattice

Current High Density 679982 2285 36.10% 825 1460 22727 Randomised Lattice

14

Within – Lattice Generation

• Quad beam elements used - modelling with a higher number of faces causes software crashes

• Generating lattice = 10mins

• Simulation set up = 15mins

• Optimisation = 180mins

• Computational limitation on lattice density was identified using within software


Unit cell size 2mm


Beamprofile Quad


Beam count 124,272


File size

Optimisation time 180 mins

+ Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine

Arch.Build file(MTT) 205mins

15

File Fixing – Magics

Magics

10 mins

+ Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


10mins

16

File Fixing – Other Software

• Errors fixed in Netfabb (5 mins processing time)

• Overlapping/intersecting errors still seen when imported back into magics

• Programme crashed during error fixing

+ Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


10mins

17

Build Processer & Simulated Build Time – Renishaw

• MTT file generated using Renshaw’s Build Processor plug in for Magics

• Processing time of 167mins

Simulated Build Times


+ Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


10mins

167mins

18

Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


+ Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine

Arch.Build file(MTT) Timing

Comparison

STL. Workflow timings (mins)

CAD geometry 25

Withinoptimisation 205

Stl. Fixer 10

Build processor 167

AM Build simulated 1519/9005 (single blade/15 blade array)

19

Can not build component through conventional routeManual Optimisation

Automatic Optimisation

Conventional

Engine

WithinRhino


AM Machine Build

Stl.

Stl. / stp.

Stl. Build file

BetatypeEngine


+ Betatype plugin)

Conventional

Engine



FE validation

AM MachineBuild

DFX/IGES


BetatypeEngine


2120

The ChallengeAdditive manufacturing enables the ability to manufacture highly complex geometry. However, the complexity of these geometries is limited by the current workflow:

• The AM workflow requires the generation of a surface meshed geometry (usually .stl). Due to this there a limit to the achievable geometry complexity.

• Highly complex/dense lattice structures are extremely time consuming to computationally validate through conventional finite element techniques.

• Build times increase exponentially with geometrical complexity

MTC’s Solution• In the partnership with Betatype, the MTC developed

a workflow that was based around Betatype’s Engine software, through creation of a highly complex lattice demonstrator component. The workflow incorporates lattice based modelling and validation via finite element analysis whilst avoiding the bottleneck of faceted data representation.

The Outcome• A quantitative assessment of the limitations of the

current workflow

• It has been demonstrated that processing a geometry of this complexity is not manageable through the current workflow.

• A method of computationally validating highly complex lattice structures was demonstrated.

• Build speed improvements of up to 4x where demonstrated when using Betatypes generated build file, compared to the machine manufactures build file

• A demonstration of how lattice structures and additional functionality could be incorporated into an aerospace component

BenefitstotheClient• The AM designer is now able to design and validate

highly complex and efficient geometries which were previously not possible

• Build times for complex geometries are substantially reduced

2221

DISCLAMER:

The data contained in this document contains proprietary information and it may not to be copied or communicated to a third party or used for any other purpose than that which it was supplied without the MTC’s prior written consent. ©️ MTC

This project received MTC SME Reach Support. For more information, contact: [email protected]

mailto:handbook%40the-mtc.org%20?subject=MTC%20SME%20Reach%20Support%20%E2%80%93%20More%20information%20requested

Documents

Design for Additive Manufacturing - Amazon S3€¦ · Stl. / stp. Stl. Build file Betatype Engine Arch. Build file (MTT) + Betatype plugin) Conventional Engine Rhino (intra-lattice