MODSIM 3DXCONFERENCE Lightweight Engineering 

In the name of Ismael Rivero Arévalo, I am pleased to invite you to watch here the replay of the presentation he held at the Global 3DEXPERIENCE Modeling & Simulation Virtual Conference, on November 17–18, 2020.

Overview:

Simulation Environment for Virtual Fatigue Testing of Additive Manufacturing Part

Additive Manufacturing (AM) application for the aerospace industry presents a significant potential to provide substantial benefits such as shorter development process and time to market, weight-optimized designs, and on-demand spares manufacturing. Regarding the aircraft structural integrity, a key aspect in aircraft design, certification, and operation is the presence of complex patterns of defects such as lack of fusion or multiple pores and voids, which are intrinsic to the AM process and can potentially produce a major detrimental effect in the fatigue strength of AM metallic parts. These defects are process dependent and largely variable, therefore dedicated characterization and analysis is required. Nowadays, industry efforts to consolidate a reliable behavioral modeling of AM components focus on three main areas: (i) physical testing to build comprehensive databases of AM materials performance and behavior (ii) statistical data treatment to enable stochastic approaches for AM materials (iii) development of high-fidelity numerical models for Virtual Fatigue Testing (VFT) Airbus DS is developing these VFT simulations for AM metallic parts based on the Continuum Damage Mechanics (CDM) formulation at the defect and coupon scales, in order to predict the effect of AM defects over fatigue strength. This VFT simulation environment is being developed and implemented in the software PAMDEMIC (Probabilistic Additive Manufacturing Defect Modelling for Initiation of Cracking), created by Airbus DS, using Abaqus as core FE solver with add-ons based on user’s subroutines for CDM behavioral modeling and Python scripting for parametric generation of characteristic AM defects and results post-processing. PAMDEMIC is able to launch Montecarlo CDM simulations in order to perform a probabilistic evaluation of the expected fatigue life for AM metallic parts, allowing the determination of the corresponding life limits or maintenance tasks required to assure the structural integrity during the service life of the part.

Presentation Replay

@ Ismael Rivero Arévalo

Aerospace Mechanical Engineering, Airbus (Defence & Space)

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