Successful, simulation based DfAM: Combining Generative Design and Process Simulation | Hexagon
Dr. Thomas Reiher
Additive Manufacturing is known to be a promising technology due to its geometrical freedom and its overall flexibility. Without proper Design for Additive Manufacturing -DfAM-, this often proves to be quite difficult to achieve. Fortunately, Hexagon has a solution to enforce the potential of AM and can show those benefits with the optimization of a wheel carrier from a race car. Based on this, it will be shown in the session how a good and fluent simulation workflow can considerably reduce product development time of such a part, easily create competitive, lightweight designs and prevents manufacturing issues. It is shown how the development can become much more efficient while enabling a tailored and successful AM design.
With Generative Design the optimization process can be significantly improved and enhanced. Through a high degree of automation most of the known tedious manual work becomes redundant. Geometry tools help to import and manipulate existing CAD data, or to start a new model right from scratch. The generative design algorithms conduct the subsequent steps of the optimization process, automating former manual activities in optimization such as meshing and generating a feasible, direct output. The AM design intelligence make the designs being tailored for AM. Because the optimization is so fast, several different design candidates can be generated. The promising ones can be directly transferred to NURBS for further processing with the validation software MSC Nastran. The lightweight design can then be imported into Simufact Additive. This tool simulates the manufacturing and post-processing and optimizes parameters such as stress and distortion, beforehand. It tweaks the parameters so that finally there will be a repeatable, hassle-free production. This is where Design for Additive Manufacturing becomes reality, enabling the user to design and manufacture parts additively at its best, with sophisticated yet intuitive simulation technology.