Chaining and Compensation over Multiple Manufacturing Process Simulation Domains

Additive manufacturing (AM) offers unprecedented design freedom, but not without limitations. Metal AM parts generally undergo additional manufacturing processes, such as welding, heat treatment, and machining prior to end-use. Each of these manufacturing processes can have an impact on the dimensional conformance of the individual parts and assemblies.
Currently, in a simulation environment, each manufacturing process is viewed in isolation, where the output is a dimensionally correct part. The present work describes an approach wherein multiple process simulations are chained together with the goal of reaching a dimensionally acceptable part after all manufacturing processes are complete. The case presented is a generic version of an IN718 turbo-pump housing. The housing is not ideal to L-PBF print because of its size and the amount of support material required. When the part is split into four individual pieces, the entire housing can fit into one medium sized machine, and printed with minimal supports. Because it is split into four sections it requires a welding process to combine the components after the printing process.
To get the correct inputs for the additive simulation the simulation strategy begins with a welding simulation to evaluate welding parameters, sequence, and clamping/fixturing strategy. Once a stable and repeatable welding process is identified, the individual CAD geometries are then compensated for the deformation in the welding process. Next, the pre-deformed geometries from the welding simulation are used as input to the AM process simulation. The parts are compensated for the additive process and post-processing effects. In this way, the parts will have a “double compensation” applied.
After compensation, the individual pre-distorted components can then be printed and subsequently welded together using the process defined via simulation. This approach can reduce the cost, time, and effort required to reach a suitable outcome and facilitate advanced design for manufacturing.