Module 05: Evaluation of

Results

Introduction to ANSYS
Additive Print

2019R3

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 Module 05 Topics
1. Evaluation of Results
2. Pre-Additive Print
• Ribbed Cylinder
• Bracket
3. Support Angle and Distortion
4. Internal Holes
5. Conformal Cooling
6. Geometry Orientation and Build
Distortion
7. Linear and J2 Displacements
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8. Design for AM Example
9. Small Parts and Stress Relief
10. Simulation Singularities
11. Topology Optimization Issues
12. Workshop 05.1: Results
Evaluation on a Round Bar
13. Workshop 05.2: Multiple
Orientations Postprocessing
 Evaluation of Results
• Simulations of geometry built on the plate without supports gives a good
representation of build
• When simulating WITH supports the stress and strain results(vtk) that can be
downloaded and viewed are simulated with the uniform support structure and
the mechanical properties are multiplied by the support yield strength ratio,
NOT the optimized support
• To understand how the optimized support structures would change the
stress/deformation results one has to merge the optimized solid supports with
the part geometry and run a simulation as if building direct to the build plate
• There is currently not a way to read in thin wall supports but this is expected to
be provided in future releases

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 Example – Support Angle and Distortion

• Supports are necessary to fixture

the part to the base plate but
increasing supports also increases
secondary finishing and build time
• Simulation can be used to examine
how support angle changes can
affect the likelihood of blade
crashes and excessive distortion
• This can be critical for complex thin
wall parts such as turbine blades

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 Example – Support Angle and Distortion
• Impeller geometry with a 30°
support angle setting

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 Example – Support Angle and Distortion
• Impeller geometry with a
37.5° support angle setting

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 Example – Support Angle and Distortion
• Impeller geometry with a 45°
support angle setting

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 Example – Internal Holes
• With each material and set of
scanning parameters analyzing
test parts from through holes
will allow one to determine
horizontal hole diameters that
will NOT require supports for
internal channels where
supports will not be accessible
No Supports
• Show how supports can be
used to maintain circularity of
through holes

With Supports
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 Example – Conformal Cooling
• Conformal cooling allows for
optimizing cooling and flow
rates by allowing for channels
not manufacturable via
conventional methods
• However, it is usually
important that there are no
support structures inside the
cooling channels
• Powder removal from small
channels can also be an issue
• Run without supports direct
to build plate

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 Example – Conformal Cooling
• Variable wall thicknesses
result in uneven part
shrinkage
• Passages and the cross section
are no longer even or circular

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 Example – Conformal Cooling
• After cutoff displacement is worse
• Curvature at base of part
• This would suggest that thermal stress
relief prior to cutoff would be
necessary
• Geometry compensation can be used in
this case
− Uneven shrinkage will result in uneven
surface
− Additional stock will have to be added for
machining anyway
− Compensated Geometry PLUS additional
machining stock

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 Example – Conformal Cooling
• Use compensated geometry STL file plus
additional machining stock on exterior and
base

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 Example – Geometry and Build Orientation
− Can I build a part to conform to the drawing?
− Are distortions in the part occurring in non-critical locations?
− Can I remove my part from the baseplate without stress relief?
− Will my part be successful if I choose to build it using the least
number of layers (lowest profile)?
− How much support density would be required for my optimal build
orientation?

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 Example – Geometry and Build Orientation
• Links were constructed
and simulated in 4
orientations XY
• Flat – XY
• On edge XZ XZ
• Vertical ZX
ZX
• Multiangle X45
Y30
Z10

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 Example – Geometry and Build Orientation
• Displacement with Common Scale
• Hole Diameter is Critical Dimension
− Uniform color around the hole gives the best circularity

XY XZ ZX X45 Y30 Z10

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 Example – Geometry and Build Orientation
• σyy Stress Distribution
− Lower stress enables part removal from the baseplate without stress relief heat treatment

XY XZ ZX X45 Y30 Z10

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 Example – Geometry and Build Orientation
• Support structures

XY XZ

X45 Y30 Z10

ZX

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 Example – Geometry and Build Orientation
• User chooses orientation
based on their priorities
− Min Displacement = XY
− Min Residual Stress = X45
Y30 Z10
− Min Support = XY
− Min Build Time = XY

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 Example – Geometry and Build Orientation

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 Evaluating Results – Linear vs J2 Displacements
• Before and after cutoff differences
− In both the Linear and J2 simulations the after cutoff
displacement was about double the on plate displacement
− The J2 displacements in both on plate and after cutoff are
greater than those for the Linear solution Linear
• The after cutoff displacement values should be evaluated to
determine if the part will be compliant WITHOUT going through
a thermal stress relief prior to cutoff
• In some cases, small geometry for example, it may be
determined that a thermal stress relief is not required
• In most cases it is recommended that thermal stress relief be J2
performed
• The results should also be evaluated to determine if the
deformation is acceptable for use
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 Design for Additive Manufacturing
• Self supporting aircraft bracket
• The part geometry is also the
support geometry
• No need for supports
− Build direct to plate
− Support between part and base
plate only

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 Design for Additive Manufacturing

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 Design for Additive Manufacturing

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 Design for Additive Manufacturing
• Part would be difficult to finish machine
• Tooling rails added to the part to allow for
easily fixturing into CNC machine
• Flat added to top of part for locating

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 Small Part Stress Relief Requirements
• For small parts it may be
advantageous to not have to do
any secondary thermal stress
relief
• Simulate the part and evaluate
the After Cutoff Stress
Displacement results

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 Analysis Singularity Issues
• As in any simulation the input file is
as critical as the boundary
conditions
− In this case a singularity in the geometry
for the displacement and blade crash
severity was noticed in the results
− Upon further investigation it was found
that it was an error in the input STL file

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 Topology Optimization and Generative Design
• Topology optimization and generative
design is starting to be used more
often to create ideal, organic shapes
• Material is used more efficiently
• Often results in geometry with
drastically changing cross sections
• Usually want to construct with little to
no support structures
• Variable cross sections can result in
variable shrinkage/distortion in the
parts

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 Topology Optimization and Generative Design

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 Topology Optimization and Generative Design
• Suggested supports are dense
and there are high aspect ratio
supports that could be
problematic to build with rigid
recoater systems
• Results from geometrical
transitions and angles less than
45 from horizontal
• Even with topology optimized
designs it may be necessary to
redesign the part to take into
account Design for AM best
practices

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 Workshop 05.1: Results Evaluation on a Round Bar

• Please refer to your Workshop instructions

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