computer-aided design for additive manufacturing: … · quality control ship to mexico • slice...
TRANSCRIPT
Computer-Aided Design for Additive Manufacturing: Can We Exploit Shape and Material
Complexity Capabilities?
David W. Rosen
George W. Woodruff School of Mechanical EngineeringGeorgia Institute of Technology
Atlanta, GA [email protected] 404-894-9668
Georgia Tech, Atlanta, GA
Georgia Tech
Georgia Tech
• 20,000 undergraduate and graduate students
• 800+ faculty• >$300M in research funding• >$300M in research funding• Located in downtown Atlanta• GT was the Olympic Village
for 1996 Summer Games
Mechanical Engineering
• Includes ME, Nuclear Engr., Health Physics
• 85 faculty• 85 faculty• 1850 undergraduate students• 820 graduate students• 11 Research Groups (CAEDesign, Mfg,
Acoustics, MEMS, Bio, etc.)• Top 5 program
Overview• Additive Manufacturing
• Cellular Structures
– Construction
– Optimization
• Integrate Materials into Computer-Aided Design
– Simultaneous product-material-process design
– Process-structure-property relationships
• Exposure Controlled Projection Lithography
Additive Manufacturing• Class of manufacturing processes that build
parts one layer at a time.
• Stereolithography, Selective Laser Sintering, Fused Deposition Modeling, ...
AM Unique Capabilities
• Shape Complexity
• Material Complexity
• Hierarchical Complexity
• Functional Complexity
Hearing Aid Shells
CreateImpression
Scan Impression
Create CAD model
Assemble components
Fabricate shell
Invisalign Manufacturing Process
Timeline
Receiving & Dental Data Treat Aligner Order Entry Laboratory Acquisition Operations Fabrication
SLA MoldFabrication
Prepare & Slice
• STL File Generat ion• Packing (orient & place)• Support Generat ionPrepare & Slice
SLA Build
Quality Control
Ship to Mexico
• Support Generat ion• Slice Data
• Laser (Scanning)• Re-coat (dip in resin)• Sweep (remove excess
resin)• Part Removal & Post-
cure
• Verify test parts• Conduct individual mold
inspect ion
• Kit in transportation box
Overview• Additive Manufacturing
• Cellular Structures
– Construction
– Optimization
• Integrate Materials into Computer-Aided Design
– Simultaneous product-material-process design
– Process-structure-property relationships
• Exposure Controlled Projection Lithography
Cellular StructuresWhen modern man builds large loadWhen modern man builds large load--bearing structures, he uses dense solids; bearing structures, he uses dense solids;
steel, concrete, glass. steel, concrete, glass. When nature does the same, she generally uses When nature does the same, she generally uses cellular materialscellular materials; wood, ; wood,
bone, coral. bone, coral. There must be a reason for it.There must be a reason for it.
-- Michael F. Ashby, Anthony Evans, et al.; Michael F. Ashby, Anthony Evans, et al.; Metal Foams: A Design GuideMetal Foams: A Design Guide
Bone Structure Human Skull
[Gibson, 2001]Linear cellular alloy parts [McDowell, 2004]
Design For Additive ManufacturingLow volume ratio structure
(Adaptive Material Distribution)
Multi-functionality:Structure + Heat Transfer
Multi-functionality: Structure + Acoustics
Combustor liner
Design and CAD Methods
00.5
1
00.5
1
00.5
1
0
0.5
1
0
0.5
00.5
1
0
0.5
1
0
0.5
CAD Representations
• Purely geometry in CAD systems• Boundary Representation solid modeling
– all geometric details are always represented– 1-2000 geometric entities is limit
• Parametric dimensions– adjustable geometry
• Complicated topology
Freedom of CreationLoughborough Univ.
Conformal Lattice Structures
16
18
18
Paramount Industries, Inc.©2009
0
2
40
5
6
8
10
12
14
Z
X
0 2 4024
6
8
10
12
14
16
UAV & Micro-UAV Examples
Application to UAV Fuselage
Size Matching & Scaling (SMS)
1 6
4 3
2
5
Greg Graf’s MS Thesis (April 2009)
Micro Air Vehicle: Problem Definition
TailFixed support
xy
FTailFMotor
F
19
Fpayload
F Motor(N) 5.9
F Tail (N) 2.7
F Payload (N/mm2) 0.1
Target Volume (mm3) 100,000
Total Unit-Cell Count 214
Optimized MAV Fuselage
Overview• Additive Manufacturing
• Cellular Structures
– Construction
– Optimization
• Integrate Materials into Computer-Aided Design
– Simultaneous product-material-process design
– Process-structure-property relationships
• Exposure Controlled Projection Lithography
Structure-Property Relationship
Har
dnes
s
Distance from surface ( µµµµm)
Har
dnes
s
Low carbon steel Materials Chemistry and Physics, 112:1099-1105, 200 8.
Motivation
Macro-scale
Decomposition(lower resolution)
CAD system
Property
11 12 1
12 22 2
66 12
0
0
0 0 2
S S
S S
S
σε σ σ
γ
= =
S
Micro-scale
RadonTransform
WaveletTransform
MicrostructureImage
ComputationalMaterials Design
MethodsMicrostructureModel
• Fiber properties• Matrix properties
Material library
DATABASE
Process Design
Find: process variables
Satisfy: process constraints
Minimize: time, cost
Materials Design
Find: volume fractions, grain size, shape
Satisfy: compatibility constraints
Maximize: energy absorption, mech properties
Part/Product Design
Find: dimension values
Satisfy: stress, strain
Maximize: energy absorption
50
Design Problem Formulation
Multi-Objective Optimization Methods
Simultaneous Product / Material / Process Design Me thods
Common Computer-Aided Design Models for Parts and Microstructure
Encoding of microstructure using Surfacelet coefficients
“Zoom-in” and “Zoom-out” operations enabled by Surfacelet model
CAD methods enabled by geometric model based on wav elets and new surfacelets
100
150
200
250
Process ↔ Structure ↔ Property ↔ Performance
Dual-Rep Approach• Common geometric model for macro
geometry and microstructure.• Wavelets support multi-resolution
modeling. – Extend to multi-scale.– Represent distributions of material, Ω
δΩ
properties– inefficient in representing curve and
surface singularities.
• Surfacelet: proposed complement to wavelets for representing boundaries.
Ω
( ) ( )( )
− − ⋅ + ⋅ + ⋅ − = + − ⋅ + ⋅
1 2
2
1/ 2 1 1, , , , , 2
2
cos cos cos sin sin
sin cosa b r r
r x y z ba a
r x ya b
b a b a by y
a ar
Physical CaP-PHB
a) Radon transformθ
µ
b) inverse Radon transforma) Radon transformθ
µ
θ
µ
b) inverse Radon transform
Wavelet decomposition level 4Wavelet decomposition level 4
1 µµµµm1 µµµµm
120~125°135~140°80~95°45~50°
0~3° &
179~180°
θ
µ
c) inverse wavelet transform d) inverse Radon transform
Wavelet decomposition level 4
120~125°135~140°80~95°45~50°
0~3° &
179~180°120~125°135~140°120~125°135~140°80~95°80~95°45~50°45~50°
0~3° &
179~180°0~3° &
179~180°
θ
µ
θ
µ
c) inverse wavelet transform d) inverse Radon transform
Wavelet decomposition level 4
Three-CaP PHB fiber
• Compute Mechanical Property From microstructure– Resultant elastic modulus matrix*
3.93 0.793 0
– Rule-of mixture : Eeff =3.45 GPa– Inverse rule-of mixture: Eeff =1.14 Gpa
3.93 0.793 0
1 9 0.793 3.26 0
0 0 1.59
e
=
E
*Kalidindi, S.R. and J.R. Houskamp 2007
IN100 Example
0
2
4
6
0
2
4
6
0
2
4
6
8
10
z (µ
m)
0 10 20 30 40 50 60 70 800
10
20
30
40
50
60
70
80
1
2
3
4
5
6
7
8
9
10
11
12
13
14 1516
17
18
19
20
21
22
23
24
25
26 27
8
10
8
10x (µm)
y (µm)
0 10 20 30 40 50 60 70 80
a b
d
c
e
Computational Materials Design
LaserMelting
Figure courtesy Dr. Surya Kalidindi, Drexel Univers ity
Overview• Additive Manufacturing
• Cellular Structures
– Construction
– Optimization
• Integrate Materials into Computer-Aided Design
– Simultaneous product-material-process design
– Process-structure-property relationships
• Exposure Controlled Projection Lithography
Exposure Controlled Projection Lithography
Laser Computer
Collimating
Imaging lens
Resin vat
Engineered diffuser
UV irradiation
Reaction
chamberCured
Part
Glass slide
x
z
DMD
Collimating lens
A more realistic model to predict the cured shape for a given exposure profile is required
Exposure (E) Cured height (z)
??
ECPL Process Overview
UV LED Source
Beam Conditioning System
Projection System
Resin Chamber
System
DMD
Mirror
Samples Fabricated with ECPL• Lenses ranging from 100µm to 10mm in a
variety of shapes, with sag heights ranging from 80µm to 300µm
July 3, 2012 33
Real Time Monitoring System –System Overview
Resin chamber
Detector
Laser
UV Source (365nm)
Beam
system
Beam conditioning
systemDMD™
Projection system
EExposure xposure CControlled ontrolled PProjection rojection LLithographyithography Patent Pending
Real Time Monitoring System (Discrete point)
Patent Pending
• Optical Path length, L = nt• Round trip optical path length:(4ngtg + 2nctc)• Change in optical thickness by photocuring, ∆L=2∆nctc
Working Principle
Detectorc c
• Phase shiftØ=2 π ∆L / λØ=4 π ∆nc tc / λ
July 3, 2012 36
Detector
Laser
Patent Pending
tc, nc
• n : refractive index• t : thickness tg, ng
Experimental Results
July 3, 2012 37
Snapshot of measuring the cured
part from confocal microscopeEstimated
HeightMeasured
Height
105 µm 100 µm
64 µm 66 µm
Conclusions• Cellular materials are basis for lightweight structure
design: repeated units arrayed along surfaces or fill volumes.
• TrussCreator NX: plug-in for commercial CAD that enables design, FEA, optimization of lattice structure.
• Take Advantage of AM geometric freedom.• Take Advantage of AM geometric freedom.
• Size Matching & Scaling optimization method is efficient (2 variables) and effective.
• Progress toward material (process-structure-property relationships) integrated into Computer-Aided Design systems.
Paramount Industries, Inc.©2009
Roadmap for Additive Manufacturing Workshop
March 2009, US NSF, ONR funded
http://www.wohlersassociates.com/roadmap2009.html
Thank you!Acknowledge:
RPMI Industry Members: 3D Systems, CIBA Vision, Ford, Pratt & Whitney, Paramount Industries
NSF IIS-0120663, DMI-0522382, CMMI-1030385
Post-Docs:Scott JohnstonFei Ding
Students:• Hongqing Wang (PhD, 3D Systems)• Benay Sager (PhD, McKinsey)Fei Ding
GT Collaborator:Yan Wang
404-894-9668 [email protected]
• Benay Sager (PhD, McKinsey)• Chris Williams (PhD, Virginia Tech)• Jane Chu (MS, Michelin)• Greg Graf (MS, Rockwell) • Sarah Engelbrecht (MS, Northrop-Grumman)• Namin Jeong, Patrick Chang, Jason Nguyen• Amit Jariwala