An end to end platform for the industrialization of additive manufacturing

Online since 07 April 2021

Article

Abstract

In the field of AM, and specifically metal Powder bed fusion, which is the subject of this presentation, a lot of progress has been made. Today, for example, AM allows us to have affordable low volume production, and new design methods allow for optimal designs that were not manufacturable before. But in order to make the next step and go to zero inventory or individualization of products, it is the view of Siemens that a more integrated and automated software process chain is needed. In general, todays’ software chain, is too fragmented and does not allow updates in the design to move quickly through the entire production chain. 

In this presentation we will show our End-to-end platform applied to a combustion chamber from a Siemens Energy gas turbine.  In this example we move from virtual product to virtual production to production planning to physical production, while the entire chain is integrated and managed in one unique environment. One of the main functionalities needed for AM is the ability to design for AM, which means CAD functionalities, topology optimization and the ability to integrate lattice structures. The designed part is then connected to production preparation and process simulation in an associative way, i.e. an update made to the design, at a later stage, will propagate through the chain automatically. One special point of focus is the possibility to remove support structures in an automated way, in order to fully automate the chain and to be able to scale up production to cost and quality.

In the second part of the presentation we focus on process simulation, because in order to reach first time right printing, we need to predict problems like re-coater collision and part distortion. If these problems cannot be predicted accurately, they will have to be solved on the printer by printing the parts, and thus impeding industrialization of quick design updates. For the distortion analysis we use an enhanced inherent strain method using a full thermo-mechanical analysis. We initially focus on the thermal analysis, in order to tackle local overheating. Local overheating is closely linked to re-coater collision, together with global distortion. The quality of the global distortion is also important of itself, because it allows us to pre-distort the part before printing and obtain a geometry close to nominal geometry after printing.

References

Electronic reference

Tom Van Eekelen, « An end to end platform for the industrialization of additive manufacturing », ESAFORM 2021 [Online], Online since 07 April 2021, connection on 25 September 2021. URL : https://popups.uliege.be/esaform21/index.php?id=4633

Author

Tom Van Eekelen

Siemens Belgium

Contact: tom.vaneekelen@siemens.com

By this author

Details

Title
An end to end platform for the industrialization of additive manufacturing
Language
en
Author, co-author
Tom Van Eekelen,
Publication date
07 April 2021
Journal title
ESAFORM 2021
Copyright
CC-BY
Permanent URL
https://popups.uliege.be/esaform21/index.php?id=4633

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Cite

Eekelen, T. (2021). An end to end platform for the industrialization of additive manufacturing. Paper presented at ESAFORM 2021. 24th International Conference on Material Forming, Liège, Belgique.