After running several optimisation scenarios and choosing the final design of a part, the manufacturing process can be simulated with Simufact Additive. For this the Print-Geometry with all Machining Allowances should be used. With Simufact Additive is capable of simulating the selective laser melting process as well as the binder jetting process for metals can be performed. The process simulation can provide information regarding the distortion, temperature or any manufacturing issue issues like a recoater contact.
Furthermore, a distortion compensation can be done. This results in a pre-compensated geometry which should be used for the manufacturing. This geometry takes all deformations during the manufacturing process into consideration to create a suitable geometry with less distortion to fulfil the tolerances of shape and position.
Example Workflow
In the following the Part Consolidation example is used for the selective laser melting process simulation.
With Simufact Additive the final optimised part design can be imported as a STL-file or a NURBS-Geometry. Custom machines can be set up or one machine and setting can be chosen from a large selection from of all well-known machine manufacturers.
The part can be orientated oriented freely in the building space. Moreover, the orientation assitant assistant can be used to find a suitable direction. Especially, for generative designed parts the orientation assistant can help to find the best building position regarding self-determined criteria which are not always immediatley immediately recognizable by visionsight.
In this case the best position is determined regarding support area, support volume and build risk. With the 3D ball in the upper left corner, the position can nearly seamless be varied nearly seamlessly.
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In Simufact Additive support structures can be created automatically or already created ones can be imported.
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From the Simufact Material library default materials can be chosen or new materials can be implementeddefined. In this case AlSi10Mg alloy is selected.
In the next step the manufacturing and optimisation stages can be set up. The distortion compensation can be activated for example. After the first run through a pre-distorted shape will be analysed. If this shape fits the conditions (e.g. max. 0.2 mm distortion) the final print-shape is determined.
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The stages of the building process can be set. In this regard stage the cutting from the baseplate and the support removal settings can be set which also have a big impact on the manufactured part.
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When the initial shape would be manufactured, a distortion from of around 1 mm can be expected. Simufact Additive creates a pre-compensated geometry and runs once again a the manufacturing simulation.
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This is just an example workflow how a process simulation can be useddone. For more information regarding Simufact Additive please contact the Simufact Additive Team.
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