Guest blog by Dominic Gallello, CEO of MSC Software
我们是一个有趣的运动，3D打印或建设新事物的添加剂制造（AM）过程的见证人。当我们看到它只是一个技术进步炒作的下一次工业革命，有一点变得非常清楚。仿真工具，使我们获得了部分“首次对”非常多的AM真正腾飞的先决条件。
回答的问题
Around the globe, I see companies taking their best people and put them into a new focus area of additive manufacturing. There are budgets but not great experiences – yet. These companies are trying to gain enough experience to answer questions like:
- 什么样的机器买？
– What are “AM friendly parts” considering factors like lot size, material, complexity, dimensions, assembly, tolerances, cost and tooling time.
- 子组件可部件数量减少？
– Can weight be saved without compromising part performance?
未能产生正悄然发生
这是很难每周通过不另一个新闻稿关于3D打印，它会导致制造革命。令人兴奋，因为上午是，用满车，桥梁和公共汽车印刷的激动人心的故事，还有更多的“悲惨故事”在印刷金属部件实现生产水平方面。公司试图跳，并获得经验已经证明非常昂贵。失败，裂缝，在意想不到的领域高失真是学习过程的一部分。
Take setting the machine parameters of a high capacity metal AM machine as an example. There can be up to 200 of these input parameters that can affect the outcomes of the resulting parts! Simply positioning the part and the location of support structures could make a big difference between getting it right and getting it wrong. Positioning the part wrong can result in an up to 160% increase in energy consumed. Today’s reality is that perfecting the AM production of a bracket could take up to two years.
Getting it wrong is expensive
Considering that current speeds for AM production of metal parts can take 1 to 2 days, the cost of getting it wrong in terms of machinery, material and power is significant. According to a December, 2014 National Institute of Standards and Technology (NIST) report:
– Metal parts made from aluminum alloys was ~$3 per part for traditional manufacturing and ~$29 per part for additive manufacturing using selective laser sintering – a 10X cost increase.
- 对于添加剂制造的塑料，主要的成本是每部机器成本，这是58.7％和成本的65.9％之间，并且每部分的材料成本，这是29.1％和成本的30.4％之间。在P730是成本有效的73 000或更小的生产量，而P390是成本有效的用于87 000或更小。
- 能耗是在考虑相比，制造业的其他方法的添加剂制造成本的重要因素，尤其是在检查从摇篮成本到坟墓的条款。
Getting it right going forward
为了让部分“一次成功”有一些必须考虑四个重要的发展：
1) Material engineering- to design optimal microstructures.
2) Topology and shape optimization – to design lightweight parts that retain structural integrity and potentially decrease part counts in sub-assemblies.
3）过程模拟 - 要基于零件设计，支撑结构安置和机器状况预测部变形
4）部分的性能 - 检查基于所述的设计和制造过程中都的部分的结构的完整性。
大部分的注意力都集中围绕拓扑和形状优化。已经有这么多的期望形怪，但结构合理的部分可以在计算机上生成。哪些公司是来学习的是，刚准备从CAD到STL机器是绝不足够。大认识到制造商来是占用一个昂贵的机器，并延迟上市时间之前，它是至关重要的，首先运行过程的模拟。
Successful simulation requires software tools that have to cover these minimum areas of capacity:
– Help the user to position parts most appropriately for the machine parameters
– Create only the support structures substantially needed to minimize distortion and prevent build job abortion.
– Provide analysis results fast enough to guide the users’ decision making. The most value in results is now, and the value of the results decreases with each hour and day that passes.
– Ease of use in the proper set up of manufacturing parameters, which are key to achieving repeatability
– Simulation of the whole post manufacturing process, including the Hot Isostatic Pressure (HIP) process to reduce the residual stresses in the part and insure that there is no porosity, and the cutting process, which takes the support structure away from the part and also potentially takes away stiffness.
– Prediction of the microstructures in the part
一个新的超级英雄将会出现
那么，谁是可以确保的是，当部分被发送到机器，它会出来完美的工程师？它是一个CAD设计师，谁将会学到很多新的技能，仿真和制造？它是一个模拟的分析师谁需要承担更多的初始部分设计的一个角色？我觉得这个超级英雄将来自两个领域，但它必须是谁的人有一个灵活的头脑是学习新方法，茁壮成长。
The future is very bright
生命体征都是积极的。机器速度will get dramatically faster while machine and material cost will continue to decline. Simulation applications will evolve rapidly to ensure “first time right.” In 1993, Apple introduced the Newton, the predecessor to the iPhone. It was a terrible failure. When the iPhone 3Gs were launched in 2008, Apple sold more than 1 million iPhones in just one weekend. Today, nearly 1 billion phones have been sold. So, it was not the hardware but the network speed and the applications that were key to the success – refinement in performance, usability and function. With additive manufacturing, I believe we are leaving the Newton age and moving toward the age of iPhone over the next 5 years. With rapid advancement of predicative applications to guide the user, the next manufacturing revolution is almost upon us.
MSC Software
mscsoftware.com
提起：3D printing • additive manufacturing • stereolithography那使零件快速那Flanges • supports • mounts • brackets
