Page 14 - 3D Metal Printing Spring 2017

3D FEATURE
Quick Simulation
Pays Dividends
Able to rapidly assess part buildability and performance, simulation software is an ideal addition to any AM user’s toolkit. BY LOUIS A. KREN, SENIOR EDITOR
For many, additive manufacturing (AM) is envisioned as a process that can simply print a print. From CAD to STL to the machine and, voila, here’s your part, right and proper and good to go for you and your customer alike. There’s an expectation that the odd- looking part, created on a computer, can simply be replicated in an AM machine. Perhaps it’s unfortunate that the term 3D printing has taken hold. It implies a process similar to that of a paper copy machine. But, as those in our industry find on a daily basis, nothing is further from the truth. From automotive to recreation
to aerospace, AM challenges abound. How then can we protect ourselves from frustrating trial and error and wasted machine time, not to mention wasted labor and material? This is where simu-
lation shines.
Captures Distortion and Residual Stresses
In a recent webinar, Arjaan Bujik, MSC Software’s business development manager for Simufact, which is simulation software for metal-manufacturing process chains including AM, identifies three challenges where 3D-printing simulation can assist:
1) Distortion. During the build, parts tend to bend out of tolerance.
2) Residual stresses. Stresses during build can lead to part failure, cracking and other unfortunate events, or support failure.
3) Quality. When 3D printing, material is created as the part is created. For an ideal, high-quality part, the material must meet porosity, microstructure and other requirements.
Proper simulation, performed at the ideal point in the design-build timeline, can optimize the metal-AM process, pro- viding accurate results while reducing
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3DMPmag.com
Fig. 1—A quick simulation of an aluminum aircraft bracket identifies areas of distortion.