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May 30, 2017 Today little CAD interoperability with AM 4 One way information flow HORIZON 2020 The STLwall Input to AM Process Planning brep type CAD only is most often a tessellation represents the shell of the

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May 30, 2017

HORIZON 2020

This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Tor Dokken, SINTEF Digital, Norway tor.dokken@sintef.no

Computer Aided Technologies for Additive Manufacturing

Dagstuhl seminar 17221 Geometric Modelling, Interoperability and New Challenges

http://www.CAxMan.eu 09/2015‐08/2018. This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • Scale
  • Descriptions
  • Methods
  • Analysis
  • Abstractions
  • Semantics

Current representations cannot handle complexity of micro‐ structure in conjunction with a larger structure Source for slide: Jan Vandenbrande, DARPA, presentation at SIAM GD, Salt Lake City, October 2015

Immediate challenges to CAx* for AM

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

* CAx – Computer Aided Technologies

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This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Solid modelling CAD (b‐reps)

  • Based on Ian Braids PhD (1974)
  • Describes volumes by the outer and inner

surfaces

  • Assumes the material is uniform throughout

the object

  • The principle behind current state‐of‐the‐art

CAD

  • Augmented with B‐splines/NURBS in the

1980s

  • CAD‐models in STEP ISO 10303 described

using b‐reps, 1990s

  • B‐reps based CAD was well established

before AM was born

  • Current CAD‐system are based on ideas of

the 1970s and 1980s

CAD evolution

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

CAxMan builds Isogeometric CAD (3‐variate)

  • IsoGeometric Analysis (IGA) by Prof Tom

Hughes (2005)

  • Replaces traditional shape functions in

Finite Elements by B‐splines from CAD, significant increases in analysis accuracy

  • Opens up for 3‐variable isogeometric CAD

where material properties can vary continuously throughout the object

  • Proposed as extensions to ISO 10303‐42

and 10303‐242 by FoF project TERRIFIC (To be published in 2017 and 2018)

  • Further extensions to STEP on

IsoGeometric CAD for AM to ISO 10303‐ 242 edition 3 planned by FoF project CAxMan in 2018 3

This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • b‐rep type CAD only

represents the shell of the volume

  • To update a CAD‐model from

AM Process Planning is very complex

  • Design of support structures,

complex inner structures and anisotropic material very limited in current CAD

  • Support structures are

today designed as part of process planning

Today little CAD interoperability with AM – One way information flow

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

The STL‐wall Input to AM Process Planning is most often a tessellation (triangulation) of the CAD‐ geometry

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This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Highlights Analysis based design (WP2)

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

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  • 3. Isogeometric

analysis direct on design geometry

  • 2. Generation of

trivariate model for analysis and multi‐ material representations

  • 1. Automatic placement
  • f cavities for reduced

material usage B‐rep CAD input Enablers for design

  • ptimization

loops

Three main research and development areas that enhance the analysis‐based design workflow

This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • To combine current CAD technologies and novel design approaches to support the

shape flexibility provided by both state‐of‐the‐art and upcoming Additive Manufacturing technologies.

  • To introduce a tri‐variate shape representation built on the upcoming isogeometric

analysis extension of the STEP standard, supporting user controlled material properties

  • f novel Additive Manufacturing technologies.
  • To integrate PDE‐based analysis into the design loop in order to optimize the shape of

the object and/or its physical properties.

  • To introduce new interactive design techniques based on subdivision volumes, in order

to fully exploit the construction of complex shapes and topologies that are enabled by Additive Manufacturing.

Analysis‐based design for AM – Objectives

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May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

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May 30, 2017

This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Simplified design workflow

Cavity structures (STEP format)

  • 1. Internal structure

modelling (Fraunhofer IGD) Input CAD model (STEP format)

  • 2. Conversion to

trivariate model (SINTEF Digital) Multiblock / trimmed trivariate model WP3, WP4, WP5 and WP6 processes Preparation for process planning (meshing)

  • 3. Isogeometric

analysis (CNR‐IMATI Pavia) The three main activities in the design workpackage are:

  • 1. Design methods for subdivision entities targeting cavity placement
  • 2. Trivariate modelling of design geometry with B‐splines
  • 3. Simulation of functional properties via IGA

Revision requests for redesign

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May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • 1. Modelling of internal structures (cavities)

Different cell configurations can be chosen

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  • Main activity in "Subdivision Volumes" and "Design for Additive Manufacturing".
  • Current implementation of automatic cavity placement based on:
  • regular voxel grid
  • collision detection/inside‐outside computation
  • geometric boundary conditions (e.g. minimal wall thickness).
  • Internal structures are exported as STEP (ISO 10303) B‐spline patches.

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • 1. Modelling of internal structures (cavities)

e.g. ‐ 22.3% material reduction (theoretical)

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  • Main activity in "Subdivision Volumes" and "Design for Additive Manufacturing".
  • Current implementation of automatic cavity placement based on:
  • regular voxel grid
  • collision detection/inside‐outside computation
  • geometric boundary conditions (e.g. minimal wall thickness).
  • Internal structures are exported as STEP (ISO 10303) B‐spline patches.

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • 1. Modelling of internal structures (cavities)

10

  • Main activity in "Subdivision Volumes" and "Design for Additive Manufacturing".
  • Current implementation of automatic cavity placement based on:
  • regular voxel grid
  • collision detection/inside‐outside computation
  • geometric boundary conditions (e.g. minimal wall thickness).
  • Internal structures are exported as STEP (ISO 10303) B‐spline patches.

e.g. ‐ 18.4% material reduction (theoretical)

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • 1. Modelling of internal structures (cavities)

Potential technological impact:

  • Better control for inserting topologically complex internal structures in objects at different

levels of detail

  • Avoiding trapped powder in manufactured part

Potential social/economic/competitive impact:

  • Less material usage/wastage
  • Less energy usage (both in production and operational lifetime, e.g. lighter components)

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  • Main activity in "Subdivision Volumes" and "Design for Additive Manufacturing".
  • Current implementation of automatic cavity placement based on:
  • regular voxel grid
  • collision detection/inside‐outside computation
  • geometric boundary conditions (e.g. minimal wall thickness).
  • Internal structures are exported as STEP (ISO 10303) B‐spline patches.

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • 2. Conversion from CAD to trivariate model

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B‐rep CAD (SotA) Pure multiblock model Hybrid trimmed /multiblock model We plan to propose this extension in edition 3 of ISO 10303‐242 in 2018 STEP ISO 10303‐42 and application protocol for Managed model‐based 3D Engineering (ISO 10303‐242)

  • Main activity in"Interoperability to CAD" and "Trivariate Shape Representation".
  • Currently working on methods for generating multiblock models where possible

and trimmed models for complex cases.

  • Trivariate models support direct simulation and potential for advanced multi‐

material representations.

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

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May 30, 2017

This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

IGA representation in CAxMan: Example part of nutating gear

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

13 Part of gear as a composition of matching spline volumes Part of gear as one trimmed spline volume The trimmed spline volume with trimming surfaces

This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • 2. Conversion from CAD to trivariate model

CAD volumes with more than 6 sides.

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CAD components with degeneracies

  • Main activity in "Interoperability to CAD" and "Trivariate Shape Representation".
  • Currently working on methods for generating multiblock models where possible

and trimmed models for complex cases.

  • Trivariate models support direct simulation and potential for advanced multi‐

material representations.

Challenging cases

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • 2. Conversion from CAD to trivariate model

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Potential technological impact:

  • Interoperability with traditional CAD systems
  • Robust (watertight) geometric models
  • Increased shape flexibility and complexity
  • Enabler for automated shape optimization
  • Enabler for description of graded materials

Potential economic/competitive impact:

  • Industrial uptake of advanced methods
  • Reduced costs via reduced engineering time
  • Main activity in "Interoperability to CAD" and "Trivariate Shape Representation".
  • Currently working on methods for generating multiblock models where possible

and trimmed models for complex cases.

  • Trivariate models support direct simulation and potential for advanced multi‐

material representations.

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • 3. Isogeometric analysis

Isogeometric analysis Multiblock decomposition of STAM bevel gear Linear elasticity test, magnitude of displacement (x400). Stationary heat test with external heat exchange

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  • Main activity in "Analysis Tools for Design" and "Tools for Optimization"
  • Initial focus was on implementing IGA solver for thermal and linear elastic

equations on multiblock geometries.

  • Currently working on extending the IGA solver to support trimmed trivariate

geometries.

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • 3. Isogeometric analysis
  • Main activity in "Analysis Tools for Design" and "Tools for Optimization"
  • Initial focus was on implementing IGA solver for thermal and linear elastic

equations on multiblock geometries.

  • Currently working on extending the IGA solver to support trimmed trivariate

geometries.

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Reparametrization methodology Accurate numerical integration is based

  • n approximation of

trimmed geometries

Initial approach: adaptive numerical integration for IGA on trimmed entities

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Quadrature over the trimmed spline volume

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

18 Part of the model Sub volumes for quadrature in 3D for the part to the left Subvolumes for quadrature in the trimmed volumetric parameter domain

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May 30, 2017

This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • 3. Isogeometric analysis

Potential technological impact:

  • Geometric quality is preserved through the simulation phase
  • Provides possibility for feedback & optimization loops
  • Avoid costly mesh conversion for each redesign cycle

Potential economic/competitive impact:

  • Reduced number of physical manufacturing trials
  • Reduced costs via reduced engineering time

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  • Main activity in "Analysis Tools for Design" and "Tools for Optimization"
  • Initial focus was on implementing IGA solver for thermal and linear elastic

equations on multiblock geometries.

  • Currently working on extending the IGA solver to support trimmed trivariate

geometries.

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Development status

  • Development up to now has mainly occurred offline:
  • GoTools – SINTEF's C++ library for geometric modelling
  • IGATools – CNR‐IMATI's C++ library for isogeometric anaylsis
  • Subdivision Tool (unnamed) – Fraunhofer's tool for design and visualisation of

subdivision volumes.

  • TopSolid – Missler's CAD/CAM software.
  • Progress has been made on integration of software components:
  • GoTools ‐> IGATools ‐> TopSolid
  • Several services are being implemented in the CAxMan infrastructure:
  • Trivariate model generation.
  • STEP‐to‐g2 converter (internal format).
  • Tessellation of STEP CAD files.

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May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Cloud Infrastructure

  • Multilayer architecture
  • Access to services from different IT‐

technology partners via the Cloud

  • Integrated workflow engineering

workbench

  • CAxMan portal with a common look and

feel

  • Generic High Performance Computing

(HPC) Service to execute complex computing tasks on an high performance cluster

  • Infrastructure synergi with
  • fp7 IP CloudFlow (2013‐2017)
  • H2020 Innovation Action

CloudiFacturing (2017‐2020) (under contract negotiations in May 2017)

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

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This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Highlights Process Planning

  • As automatic as possible PP
  • User is called into play only if

problems arise

  • CAxLib C++ library
  • To handle annotated tessellations
  • Most PP services are based on it
  • Virtual prototypes
  • To foresee how prototype will

appear

  • Appropriate for thermal‐stress

analysis

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

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This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Highlights Thermal and stress analysis

  • Description
  • Thermal analysis framework for AM

process simulation

  • Residual stress module for AM process
  • Software module for Heat Treatment

analysis

  • Target
  • Simulation strategy for simplified analysis:

Inherent strain methods

  • Suitable for powder bed AM technologies

(e.g., EOS‐280)

  • Very fast solution (e.g. minutes, hours)

suitable for optimization loop

  • HPC‐implementation for industrial analysis

& cloud computing

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

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This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Highlights Dimensional Quality

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

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3D Scanning Deviation Map GD&T

Dimensional Analysis Workflow First experimental validation Use and contribution to International Standards

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May 30, 2017

This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Highlights Numerical Control

  • Dimensional analysis
  • New stock definition
  • Surfaces simplification
  • Tool path strategy
  • Finishing based on IGA

technology

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

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This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Use case: NUGEAR

The NUGEAR is an innovative gearbox, patented by STAM, which couples the mathematical concept of nutation with bevel gears.

May 30, 2017

Difficult to produce with standard manufacturing (small parts, undercuts). Intensive simulations and

  • ptimization loops

required.

Dagstuhl seminar 17221 Geometric Modelling

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This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • Decrease the manufacturing cost (‐20%) and time (‐40%)
  • Allow perfect balance of nutating parts without manufacturability constraints
  • Reduction of parts weight (overall ‐25%) through advanced inner structures in

the volume of the gears

  • Improvement of transmission quality (reduced edge contact) and operational life

through tooth shape optimisation

  • Reduced engineering time (‐15%) through increased interoperability among

design‐development steps

Target for impact in CAxMan

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

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This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Injection Mould

The mould is the core of thermoplastic injection technology. After closing, the mould is filled with molten plastic under pressure, cooled by water and opened to eject the produced part.

May 30, 2017

Structural, thermal and fluid dynamics analyses are required Complex geometries, undercuts, moving parts, cooling channels

Dagstuhl seminar 17221 Geometric Modelling

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This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

  • Optimised design of the cooling system (cooling time reduction: 35%, cycle time

reduction: 10%) and of the designable shapes in general, without manufacturability constraints

  • Weight saving (‐50%) by creating a dedicated “structural mesh”, outside of which

material is not necessary.

  • Waste material saving (up to 90%) in cavities finishing.
  • Finishing need: some surfaces have to be polished for functional (closure),

aesthetic and kinematic reasons.

Target for impact in CAxMan

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

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This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.

Highlights Standardization

  • Continual, active involvement in ISO standards resulting in:
  • ISO 10303, STEP, Application Module for Additive Manufacturing – Initial Draft

Completed

  • ISO 10303‐209 (Multidisciplinary analysis and design, AP209)
  • Validated by CAxMan
  • FoF STREP TERRIFIC follow‐up in CAxMan
  • ISO 10303‐42 including Isogeometric CAD – to be published in 2017
  • ISO 10303‐242 including Isogeometric CAD – to be published in 2018
  • ISO/TC 184/SC 4 agreed to set up project to complete IGA inclusion into ISO

10303 in response to augement the TERRIFIC initiative through CAxMan

  • Other dissemination focused on creating awareness of CAxMan in relevant

communities

  • Saving dissemination and outreach resources to support exploitation in the second

half of CAxMan

  • Dissemination activities reported in PPR

May 30, 2017 Dagstuhl seminar 17221 Geometric Modelling

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May 30, 2017

HORIZON 2020

This project has received funding from the European Union's Horizon 2020 research and innovation programme under grant agreement No 680448.