Virtual Prototyping & Rapid Prototyping
- 1. Virtual Prototyping & Rapid Prototyping Jonathan Prince & Greg Morehouse
- 2. What are we talking about? • What is Virtual Prototyping from an engineering perspective? • Simulation of Rapid Prototypes • Why perform Virtual Prototyping and Rapid Prototyping? • Time to market • Accuracy of design • Risk mitigation • Virtual Prototyping Process - Bogie Case Study!
- 3. VIRTUAL PROTOTYPING Types of Virtual Prototyping • Stress (Structural) Analysis (FEA) • Understand the effects of possible loads and restraints early • Remove unnecessary weight & material • Flow Analysis (CFD) • Fluid flow, losses, flow lines, heat transfer, turbulence • Coupled Fluid / Structural Interaction (FSI) • Mold Flow Analysis • Will the mould fill? • Will the part last? • Computer Aided Machining (CAM) • Can the mold / part be made?! • Risk Mitigation • Get it right for final (productionised) prototyping!
- 4. RAPID PROTOTYPING STRUCTURAL SIMULATION Especially for Additive Manufacture! • Understanding the layered build process • Understanding the difference in material properties - strength, ductility & stiffness • Isotropic, Orthotropic vs. Anisotropic? • Non-Linear materials properties • Simulating fatigue • Simulating creep • Pitfalls for the uninitiated!
- 5. VIRTUAL PROTOTYPING? Nah, I’ll just whip one up! http://www.3ders.org/articles/20121204-tested-3d-printed-gun-breaks-within-6-shot.html
- 6. RAPID PROTOTYPING SIMULATION Especially for Additive Manufacture!
- 7. VIRTUAL PROTOTYPING & RAPID PROTOTYPING Why are they important? • Time to market • Crucial to product profitability • Accuracy of design • Crucial to the brand, the product and success of the company • Mitigating risk • What will it cost if you get it wrong?
- 8. RAPID PROTOTYPING Tensile Strength Optimisation From: http://www.sculpteo.com/blog/2014/05/14/right-plastic-production-method-part-3/ Part and material properties in selective laser melting of metals Jean-Pierre.Kruth@mech.kuleuven.be
- 9. RAPID PROTOTYPING Techniques From: http://www.sculpteo.com/blog/2014/05/14/right-plastic-production-method-part-3/
- 10. RAPID PROTOTYPING Unexpected Results! From: http://www.sculpteo.com/blog/2014/05/14/right-plastic-production-method-part-3/
- 11. RAPID PROTOTYPING Additive Manufacturing Risks From: Thinking ahead the Future of Additive Manufacturing – Analysis of Promising Industries
- 12. Risky? Really?! Risk: The probability of something happening multiplied by the resulting cost ($$ or life) if it does.
- 13. Why is virtual and rapid prototyping important? Accuracy of Design
- 14. Fit for Purpose? • Do things Fit? • Design Intent: Do they work as intended? • Can it take the loads? • What are the loads, how is it used and restrained? • Can it handle the environmental conditions? • What are the long term, ongoing scenarios? • How might this be used & abused? • Rubbish in = rubbish2 out
- 15. Analysis process • Progressive
- 16. Analysis process • Progressive • Conservative railpictures.net image © phil cotterill
- 17. Analysis process • Progressive • Conservative • Controlled
- 18. Analysis process • Progressive • Conservative • Controlled • Validated
- 19. Over the Top? Design without analysis is like pilots without instruments; they know they’re flying, but they might not know exactly where they are!
- 20. Summary • Build virtual prototyping and rapid prototyping into your development process! • Don’t skimp on the engineering • Rubbish in = rubbish2 out • Develop a virtual prototyping methodology • Get it right before you cut steel or inject plastic!