Stabilizing Additive Manufacturing Simulations with Finite Element Elements
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Solution Overview
Problem
Additive manufacturing techniques face challenges in simulating the build of 3D objects due to numerical instability, leading to incomplete simulated models and increased waste of time and materials, as existing methods struggle to handle rigid body motion and element orientation issues during the simulation process.
Innovation Solution
The method involves modifying finite element models by adding stability elements, additional elements, or one-dimensional elements to reduce rigid body motion, ensuring that the simulation can generate a complete and accurate digital model of the object by stabilizing elements with numerical instability, such as floating nodes or uncoupled elements, and adjusting element orientations to improve contact between elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard finite element models are used for additive manufacturing simulation, then the simulation can be performed, but rigid body motion and numerical instability cause the simulation to fail or produce incomplete models
Solution Approach 1:
The patent applies preliminary action by automatically detecting and correcting model issues before the simulation runs. The system identifies floating nodes, uncoupled elements, and improper element orientations in advance, then automatically adds stability elements or adjusts the model to prevent rigid body motion before simulation begins, ensuring complete and reliable simulated models are generated.
2Loss of time
If simulations are performed to avoid build failures, then time and materials are conserved, but numerical instability causes simulations to abort before complete models are generated
Solution Approach 1:
The patent implements feedback by automatically analyzing the finite element model for numerical instability issues such as floating nodes, uncoupled elements, and improper element orientations. The system provides feedback by automatically adding stability elements or adjusting the model to eliminate rigid body motion, ensuring the simulation completes successfully and provides reliable feedback for design improvements.
3Reliability
If stability elements are added to reduce rigid body motion, then simulation reliability improves, but model complexity increases
Solution Approach 1:
The patent applies self-service by implementing automatic detection and correction of model issues. The system autonomously identifies floating nodes, uncoupled elements, and improper element orientations, then automatically adds stability elements or adjusts the model without requiring manual intervention, thereby reducing the overall complexity burden while ensuring simulation reliability.
Data Source
AI summary
A system and method for automatically reducing rigid body motion in a digital simulated model of an object, where the simulated model represents a simulated build of the object using additive manufacturing.