Additive manufacturing simulation with Abaqus AM modeler plugin

3D printing simulation using the Abaqus AM Modeler plugin

The Abaqus AM Modeler plug-in offers a streamlined, user-friendly approach for simulating additive manufacturing processes, minimizing errors and complexities. Unlike the challenges of coding or Python scripting, this plug-in simplifies simulation setup. Users only need to input data, create the job, and initiate the simulation.

The Abaqus AM Modeler utilizes two primary 3D printing simulation methods: eigenstrain and thermomechanical. Each approach supports specific process types to suit varied user needs. The eigenstrain method includes two process types: trajectory-based and pattern-based, ideal for users needing fast, efficient setups. The thermomechanical method expands this with four process types: trajectory-based powder bed fabrication, pattern-based powder bed fabrication, laser direct energy deposition, and fusion deposition modeling.

Workshops of the Abaqus AM Modeler plug-in

This method involves three primary workshops: “Sequential thermomechanical analysis of simple cube one-direction LPBF 3D printing using the trajectory-based method with AM plug-in,” “3D printing simulation with Fusion deposition modeling and Laser direct energy deposition method with AM plug-in,” and “Material Removing with AM plug-in.” The first two workshops are done with two versions of the Abaqus AM Modeler: an older and a newer version. The first workshop, which involves LPBF, is carried out using the older version, while the second workshop uses the newer version. The reason for using two versions is to familiarize the participants with both versions, in case they encounter either one.

Note: 3D printing can be used to produce complex components quickly and cost-effectively, allowing for more customization and reduced lead times, right? SO, it can be a great help in Smart manufacturing! But what is smart manufacturing anyway? Do not worry because we have a complete course of it: “Smart Manufacturing Course.”

Workshop 1: Sequential thermomechanical analysis of simple cube one-direction LPBF 3D printing using trajectory-based method with AM plug-in

Laser Powder Bed Fusion (LPBF) is a 3D printing method that utilizes a high-powered laser to melt and fuse metal powders together layer by layer. The process involves spreading a layer of metal powder over a build platform using a roller, followed by scanning the powder with a high-powered laser to melt and fuse it together based on the 3D model. The platform is lowered, and the process is repeated layer by layer until the object is complete.

During the workshop, the model’s geometry and layer details are discussed, followed by presenting the required material properties. The necessary information and inputs for the roller and laser beam, including their speeds and “Event series” data, are provided. The boundary conditions are explained, and the modeling process in Abaqus begins. The simulation involves two analyses: a thermal analysis followed by a structural analysis. The required inputs, such as “Event series” data, are added via the Abaqus AM Modeler plug-in. The simulation is performed using the older version of the plug-in, and the results are discussed in the end.

Note: Did you know you can use topology optimization in for a 3D printing part? Interesting, isn’t it? Lucky for you we have course for that called: “Advanced Space–Time Topology Optimization in Multi-Axis Additive Manufacturing“.

Workshop 2: 3D printing simulation with Fusion deposition modeling (FDM) and Laser direct energy deposition (LDED) method with AM plug-in

The Fused Deposition Modeling (FDM) is a 3D printing technique that involves extruding melted filament layer by layer to create a 3D object. The process includes feeding a filament into a heated extruder (nozzle), which melts the filament and deposits it layer by layer onto a build platform based on the 3D model. The material cools and solidifies, creating the final object.

During the workshop, the model’s geometry, layering, and details such as bead dimensions are presented. Material properties are introduced, followed by the representation of nozzle data, including speed. All simulation steps are similar to the previous workshop, except for the Abaqus AM Modeler part, which uses the newer plug-in version.

In both workshops, element progressive activation technique (Material Deposition) is used for material deposition, and a moving heat source is employed for heating. Both material deposition and moving heat source have several types in Abaqus AM Modeler, which are explained during the workshops.

Workshop 3: Material Removing with AM plug-in

This workshop introduces special-purpose techniques and user subroutines for machining and material removal processes that typically follow an additive manufacturing process. The workshop teaches participants how to perform a material removal process on a simple cube using a simulation approach. The simulation involves defining a bead and an event series, along with required special-purpose techniques called “ABQs.” The bead assigns the materials that require removal, the event series defines the toolpath trajectory, and the ABQs apply these settings. The simulation also includes the progressive element activation method in a structural or thermal analysis to deactivate the elements. To perform the simulation, the required settings are first configured using the AM Modeler plug-in, the input file is generated, and then some changes are made manually to the input file before running it.

What is Additive manufacturing or 3D printing?

Additive manufacturing, also known as 3D printing, is the process of creating a three-dimensional object from a CAD model or digital 3D model. In an additive manufacturing process, layers of material are added one at a time until the final product is produced. Materials can be combined, deposited, and solidified using a variety of computer-controlled processes in this process. The materials being combined could be formed of plastics, liquids, or grains of powder that are being fused, among other things. Abaqus AM modeler is fully described in this training package.

Did you know we have 3D printing for composite materials as well?! You can learn all about it in our course: “3D Printing Composites with Continuous fiber Reinforced Structures: Design, Fabrication, and Applications“. The syllabus of this course.

Additive Manufacturing or 3D Printing simulation in ABAQUS

Why is Abaqus needed to simulate 3D printing? We do different simulations for the same reasons. examining the model’s deflection, the temperature, and thermal conditions, the presence of any residual stress, etc. To prevent wasting money, it is also a good idea to check that the printer’s settings match the requirements of our model before printing. conditions such as temperature and material characteristics, etc. Abaqus provides us with a great tool called Abaqus AM Modeler for 3D printing simulation.

This package will show you how to replicate the 3D printing process using the Abaqus AM modeler plug-in, which was created by Dassault Systemes.

We are Up to date!! We also have a course for 4D printing for Fiber-Reinforced Polymer Composites!!

Enroll for this advanced course to complete you education in Additive manufacturing:

“Machine Learning for Predicting Fatigue Properties in Additive Manufacturing Course“

It would be helpful to see Abaqus Documentation to understand how it would be hard to start an Abaqus simulation without any Abaqus tutorial.

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