digital twin design process for development of … · fused metal deposition am sand mold & casting...

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DIGITAL TWIN DESIGN PROCESS FOR DEVELOPMENT OF NEXT GENERATION

LIGHTWEIGHT INVESTMENT CASTED PARTS

Dr.-Ing. Santhanu Jana, Technical Consultant Manufacturing Solutions


Our Vision is to…

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Transform customer decision

making with simulation, data

analytics, and high-performance

computing.”

Jim Scapa, Founder and CEO

“

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About Altair

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$459MFY19

Revenue

3,000+Engineers, Scientists,

and Creative Thinkers

1985Founded and

Headquartered in

Troy, MI U.S.

11,000+Customers

Globally

86Offices in

25 Countries

150+Altair and Partner

Software Products


Design, Modeling & Visualization Physics Simulation Data Analytics

Internet of Things High Performance Cloud Computing Altair Partner Alliance (APA)

Broad Solutions Portfolio

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11,000+ Customers Worldwide

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Automotive Aerospace Education Energy Financial Services

Government

& Defense

Heavy

Rail

Industrial

Goods

Life & Earth

Sciences

Material

Suppliers

Technology


weld construction casting laser melting

What do these products have in common?


weld construction laser melting

What do these products have in common?

Simulation-Driven Design for Advanced Manufacturing

casting


Simulation-Driven Design for new horizons in Manufacturing

• Discuss the best manufacturing process for

the part

• Create the design for the

optimal manufacturing process

• Balance manufacturability and

performance

• Design using the freedom of modern

manufacturing


Balance manufacturability and performance

• Example:

Rear Suspension Design for Manufacturing


Simulation Driven Design & Manufacturing

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Powder Bed

Laser Melting

Metal Binder

Jetting

Fused Metal

DepositionAM Sand Mold

& Casting Machining

Thank you to all the Manufacturing partners supporting the showcase!

Design for your process


Simulation Driven Design & ManufacturingDesign for your process

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Powder Bed

Laser Melting

Metal Binder

Jetting

Fused Metal

Deposition

AM Sand Mold

& Casting

Machining

Conventional

Casting


From Design to Manufacturing

• Re-visit existing suspension component design

with a view to manufacture using casting and/or

additive manufacturing rather than machining

• Maintain at or near current performance without

and weight penalty

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Load identification

• Identify resultant loads to be applied to the

components subject to re-design

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From design to Manufacturing

• obtain the design space from original part

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From design to Manufacturing

• obtain the design space from original part

• Through design and defeature capabilities

design and non design regions

are set up in minutes

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Optimization Process

• Maximize the available design space.

• Surfaces adjacent to non-design regions were

preserved

• Original location was maintained to facilitate the

part replacement process

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Understanding Constraints & Performance

• assure manufacturability with shape controls

• shape controls influence performance weight ratio


Understanding Constraints & PerformanceMost relevant design rules for investment casting:

• Moldability:

avoid undercuts with „draw direction“

• Wall thickness:

control the „member size“

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Understanding Constraints & PerformanceSame part, different design for each manufacturing process:

Accessablity of cutting head of 3 axis mill

Avoiding Support for SLM

Room needed for gating system for casted part

Define center of gravity for FDM

to assure proper shrinkage during sintering


Compare Performance vs. Manufacturability

• Check the differences between your designs and choose the most performant one


Simulation-Driven Design for Advanced ManufacturingWorkflow

• Identification of requirements

• Generative design respecting

manufacturing design rules

• Automatic creation of geometry

• Assuring part performance

• Manufacturing feasibility checked


Simulation Driven Design & ManufacturingWhat is the best manufacturing method for your project?

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Powder Bed

Laser Melting

Metal Binder

Jetting

Fused Metal

Deposition

AM Sand Mold

& Casting

Machining

Conventional

Casting


Example - Hybrid Casting


ADAPTING DESIGN FREEDOM TO

MANUFACTURING REALITY


SLM Design vs. Hybrid Casting Design


Same part, different design for each manufacturing process:

Avoiding Support for SLM realisation

Room needed for gating system

for casting process

Adapting Design Freedom to manufacturing reality


Powder Bed

Laser Melting

AM Sand Mold

& Casting

Powder Bed

Laser Melting

AM Sand Mold

& Casting

SLM Design vs. Hybrid Casting Design


Machining

Conventional Sand Casting

Printed Mold & Casting

Powder Bed Laser Melting

Fused Metal Deposition

Metal Binder Jetting

Investment Casting

Design Rules & Manufacturing Simulation in one Flow


Design parts for investment casting considering design rules topology optimization

• Moldability: avoid undercuts with „draw direction“

• Wall thickness: control the „member size“

• Space for gating : control the „design and non-design space“

• Part detachment: control the „design space and member size“

• ……

Check CastabilityDevelop designs Investment Casted Part

Digital Twin Design Process For Investment Casting Parts


Digital Twin Design Process For Investment Casting Parts

• Integrated optimized design balancing performance and manufacturability, offers :

“a powerful business model for concurrent engineering”

• Design parts to maximize performance and efficiency and manufacturable by Investment

Casting

• Eliminate risks and costs early on and material savings

• Develop new business opportunities with organic lightweight designs


Examples from Customers using Investment Casting

Wisconsin Precision Casting Corporation

Feinguss Blank GmbHSogeclair Aerospace

digital twin design process for development of … · fused metal deposition am sand mold & casting...

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