Upload
geonx-sa
View
559
Download
6
Embed Size (px)
DESCRIPTION
GeonX is a high-tech start-up company specializing in virtual manufacturing. Created in 2012 from the enthusiasm of its two founders, and an investment by a group of private investors, GeonX develops and markets its VIRTUAL FACTORY, Virfac®. This product is based on the finite element solver Morfeo, which has been actively developed since 2003, with the aim of carrying out massively parallel simulations of various manufacturing processes. GeonX develops and distributes its integrated software solution Virfac® for simulations of welding (fusion and friction), additive manufacturing, machining, heat treatment, surface treatment, and damage resistance (crack propagation based on the XFEM). GeonX has clients in Europe, Japan, North America, in the aeronautics, automobile, naval, and nuclear sectors. GeonX’s leading aerospace client is the SAFRAN Group (France).
Citation preview
VIRFAC | The Virtual Factory
Finite Element Simulation of
Advanced Processes
Case Studies:
Welding & Additive Manufacturing
Copyright GeonX © 2014
Dr. Laurent D’Alvise
CEO & co-founder
www.geonx.com
TABLE OF CONTENTS
Cladding example
Welding example
Global picture
Virfac® | www.geonx.com
To control parts deformations during manufacturing …
Improving quality mastering before launching production !
To control residual stresses generated during manufacturing …
Assessing the impact of manufacturing on life and durability !
To understand the complex phenomena occurring during manufacturing and
the influence of process operating conditions …
Reducing scrap and improving cash return !
WELDING SIMULATION : WHY ?
© 2012-2014 GeonX – All rights reserved
Virfac® | www.geonx.com
OUR VISION
Physics simulation and modelling will help achieving these goals
GeonX is building the integrated Virtual Factory that will enable production
engineers to simulate before making !
NOT an expert tool for expert engineers
BUT a powerful software tightly integrated with manufacturing
machines and modern computing capabilities.
© 2012-2014 GeonX – All rights reserved
LET’S TAKE AN EXAMPLE !
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
INPUT DATA From: Tanker Components: 2 Stiffened Panels (AH36) Dimensions: 3,48 x 16 m Thickness: 13 mm Weld Length: 16 m Objective: control distortions
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
Live visualization of temperature, deformations,
stresses, metallurgical transformations, etc.
TYPICAL OUTPUTS
1
-6
Y [mm]
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
TYPICAL OUTPUTS
Final deformation of the stiffened panels after 1 weldline operation.
Possibility to optimize the welding sequence, operating conditions, clamping
system, jig positions, etc. in order to minimize deformations.
Particularly well suited when the structure is complex and with a high number
of welds.
VIRTUAL WELDING, OR
ADVANCED WELDING SIMULATION
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
Welding objectives:
• Minimization of distortions
• Minimization of residual stresses (crack prediction)
• Optimization of weld joint properties (hardness) and microstructure
• Verification of weldability or defaults
Operating conditions to tune/optimize:
• the welding speed/energy
• the welding sequence
• the clamping or fixture setup
• and other operating conditions, if any
OUT
IN
IN Virtual
Welding OUT
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
Private Belgian company incorporated in October 2012
Specialized scientific and industrial software editing
Development of a new generation manufacturing software:
• The Virtual Factory, Virfac® powered by Morfeo: powerful user-interface (since 2012)
• Morfeo (Manufacturing ORiented Finite Element tOol): parallel FE solver (since 2003 in partnership with Cenaero)
The Virtual Factory Virfac® addresses the following processes:
•Fusion & Friction Welding (LBW, EBW, FSW, IFW, etc.)
•Additive Manufacturing (Cladding, etc.)
•Advanced Machining
•Damage tolerance and durability
•Welding → In-service behavior (crack propagation)
•For large industrial mechanical components
•Specifically designed for High Performance Computing systems
•Extensively tested on industrial and demanding applications
•Within the industrial environment (mimetic)
GEONX IN A NUTSHELL
GEONX SOFTWARE PRODUCT
Virfac® | www.geonx.com
Morfeo Virfac®
© 2012-2014 GeonX – All rights reserved
VIRFAC® IN A NUTSHELL
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
CAD modelling
Parasolid kernel library (Siemens PLM)
Import and export of Parasolid native file (x_t, xmt_txt, xmt_bin, x_b, …)
Model transformation (intersection, union, scaling, rotation, translation, etc.)
CAD geometry entities management (creation, destruction, …)
Import of other CAD format: translators for CATIA, Pro-E, IGES and STEP
Discrete model importer with cleaning functionalities
Meshing:
DISTENE MeshGems on Parasolid model for :
Surface triangulation
3D tetrahedra meshing
Size control – Face – Edge – Node – Curvature
Anisotropic meshing
Extruded unstructured meshes
Partnership with Beta-System (ANSA mesher)
TABLE OF CONTENTS
Cladding example
Welding example
Global picture
Virfac® | www.geonx.com
The present study aims to:
1. Use Virfac Welding for an application representative aerospace interests
2. Simulate the welding process on a exhaust carter and display distortions taking place
during the welding operations
3. Verify the influence of the welding sequence on the residual distortions
4. Compare two modelling approaches from a computing performance and accuracy
standpoints
Welding sequence n°1
Welding Sequence n°2
© 2012-2014 GeonX – All rights reserved
Transient Thermo-Mechanical analysis
Inherent Strain Method
EXAMPLE N°1 - OBJECTIVES
Virfac® | www.geonx.com
A “fake” exhaust carter was designed for non-confidentiality purposes:
1. External diameter : 200 mm
2. External ring thickness : 12 mm
3. Number of welds : 16
4. Nominal sequence: shown hereafter
© 2012-2014 GeonX – All rights reserved
APPLICATION DESCRIPTION
Virfac® | www.geonx.com
Experimental data:
1. Material : steel
2. Clamping system : central core
3. Welding process : LBW
4. Welding power : 800 W
Nominal welding sequence:
1. Distortions are magnified 40 times
2. External ring strongly deformed
3. Visible rotation of the part
4. Twist of the carter
5. Computation time: 21 minutes
© 2012-2014 GeonX – All rights reserved
RESULTS
Virfac® | www.geonx.com
Influence of the operating conditions:
1. Welding parameters
2. Clamping system
3. Welding sequence
© 2012-2014 GeonX – All rights reserved
MINIMIZATION OF DISTORTIONS
Virfac® | www.geonx.com
Influence of the welding sequence:
© 2012-2014 GeonX – All rights reserved
MINIMIZATION OF DISTORTIONS
Virfac® | www.geonx.com
Influence of the welding sequence:
Changing the welding sequence leads to a reduction of distortions:
• This information may be useful to address quality issues
• This information is available through a virtual environment prior any experimental test
• Timeframe for obtaining such results on this simple application:
Set the model with Virfac: ~4 hours
Computation time: 21 minutes per simulation
• Process optimization is possible within a virtual environment: Virfac Welding Scheduler
• Further results in terms of residual stresses and metallurgy are also possible:
full transient methodology : Virfac Welding Designer
© 2012-2014 GeonX – All rights reserved
PROCESS OPTIMIZATION
TABLE OF CONTENTS
Cladding example
Welding example
Global picture
Virfac® | www.geonx.com
The present lecture aims to:
1. Apply Virfac to laser cladding simulation and predict distortions after corrective
machining.
2. Demonstrate the feasibility and pertinence of manufacturing chaining simulation.
3. Perform sensitivity studies on the operating conditions and check the influence on
quality criteria in terms of residual distortions.
© 2012-2014 GeonX – All rights reserved
EXAMPLE N°2 - OBJECTIVES
Virfac® | www.geonx.com
Machining
Simple (for validation purposes) additive manufacturing application (laser
cladding: tube on support) followed by machining.
Additive Layer Manufacturing
Distortions, Residual Stresses and
Metallurgy from the T/M/M simulation
Final part within
geometrical tolerances
© 2012-2014 GeonX – All rights reserved
APPLICATION DESCRIPTION
• Large excursions of temperature • Cycling heat load over one location • Cycling material melting & solidification • Large excursions of material properties • Important metallurgical transformations
Export : • Final geometry • Residual stresses
Virfac® | www.geonx.com
MA -
Corrective Machining
The present study aims to setup a demonstrator of process chaining simulation.
The following questions will be addressed:
1. How far the ALM part will be from the nominal geometry ?
2. How will the machining process influence the distortions of the final part ?
3. Which tolerance will be reached after machining ?
Important notice: this numerical model will be used as a simulation demonstrator and not yet for experimental validation purposes (see perspectives).
ALM -
Additive Layer Manufacturing
© 2012-2014 GeonX – All rights reserved
WORK PLAN
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
Additive Layer Manufacturing
Stage n°1: Additive Layer Manufacturing
1. Operating conditions:
Tube on plate: ext.diam. 52.4 mm, length 25 mm, thickness 2.2 mm
Material: Inconel 718
Number of cladding layers: 14
Loading speed: 13.3 mm/s
Loading time: 172 s
Post-ALM cooling time (on threshold 20°C): 1579 s
2. Modelling hypothesis:
Thermo-Mechanical-Metallurgical coupling
Transient analysis
HEXAhedra elements conforming to the clad
Automatic mesh elements’ activation according to a moving box of selection
Heat loading: energy density applied in the activated FE elements (volume)
Thermal properties as a function of temperature
Mechanical properties as a function of temperature (Elasto-Plastic # Power Law)
Distributed Multi-Processing analysis: 12 processors
SIMULATION DESCRIPTION - ALM
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
ALM sequence:
Same starting point for each layer
Same loading direction for all layers
SIMULATION RESULTS - ALM
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
Residual distortions (after ALM + cooling):
Comparison against the nominal geometry
Cross section parallel to the ALM start
Deflection at the top of the tube: -0.637 mm
Maximum deflection (radial): -0.755 mm
δtop = -0.637 mm
δmax = -0.755 mm
Cross section
SIMULATION RESULTS - ALM
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
Alternative layer sequences:
Influence on residual distortions
Configuration T2:
Same start for each layer
Alternating loading direction from one layer to the next
Configuration T3:
90° shift start for each layer
Same loading direction for all layers
Configuration T4:
90° shift start for each layer
Alternating loading direction from one layer to the next
i
i+1
i
i+1
SIMULATION RESULTS - ALM
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
i
i+1 Cross section
δtop = -0.475 mm
δmax = -0.594 mm
Reference (configuration T1): δtop = -0.637 mm δmax = -0.751 mm
Configuration T2:
SIMULATION RESULTS - ALM
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
δtop = -0.66 mm
δmax = -0.747 mm
Cross section
Reference (configuration T1): δtop = -0.637 mm δmax = -0.751 mm
Configuration T3:
SIMULATION RESULTS - ALM
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
δtop = -0.577 mm
δmax = -0.700 mm
Cross section
i
i+1
Reference (configuration T1): δtop = -0.637 mm δmax = -0.751 mm
Configuration T4:
SIMULATION RESULTS - ALM
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
Additive Layer Manufacturing
Stage n°2: Machining
1. Operating conditions:
Tube on plate: deformed from the Additive Manufacturing process
Geometry: Configuration T2 selected
Machining process: surface finish (cylindrical shape)
Thickness of removed material: 0.2, 0.4, 0.6 mm
Objective: flat surfaces
2. Modelling hypothesis:
Deformed mesh from the upstream analysis (ALM)
Residual Stresses mapped from the upstream process (ALM)
Mechanical analysis based on XFEM
Cutting passes represented by Level-Sets
Computation time : several minutes
Machining
Mesh’’
MODELLING DESCRIPTION
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved
Machining thickness sensitivity:
Effect of machining on residual distortions
Without Stress Relief Heat Treatment
The 0.6 mm thickness leads to flat external surfaces
Thickness (mm)
Rtop
(mm)
Rmin
(mm)
Tolerance (mm)
0.2 25.882 25.775 0,107
0.4 25.798 25.776 0.022
0.6 25.592 25.599 0.007
i
i+1 Cross section
Additive Layer Manufacturing
Machining
Flat surface
SIMULATION RESULTS - MA
FURTHER DETAILS
Contact details
Dr. Laurent D’Alvise
Mail: [email protected]
Skype: geonx_
Visit: www.geonx.com
Follow us on Twitter: @geonx_
Virfac® | www.geonx.com © 2012-2014 GeonX – All rights reserved