Dassault Systemes Case Study

Download as pdf or txt
Download as pdf or txt
You are on page 1of 4

Case study

Enhancing the additive manufacturing


process chain

Partnership: Challenge: Solution:


Dassault Systèmes and Aligning the performance of software Enhanced Dassault Systèmes
Renishaw modelling and design tools with real 3DEXPERIANCE platform and
3D printing processes. Renishaw AM systems.
Industry:
Automotive

Executive summary Background


The design freedom provided by additive manufacturing (AM) The 3DEXPERIENCE platform comprises a whole suite of
or ‘3D printing’ technology is an important enabler in cutting- 3D software applications supporting the complete product
edge product innovation. As part of the revolution in digital life cycle, from design and development to simulation and
manufacturing, AM can radically simplify the production of reliability analysis.
complex parts, while simultaneously improving functional
Available to users on premise or on-cloud, and accessible
performance, reducing part weight and minimising component
via a single user interface, it enables the creation of ‘social
counts.
enterprises’ where collaboration in the product innovation
To take full advantage of AM’s unique capabilities, however, process becomes simpler and more efficient.
complementary software tools need to be optimised
Topological optimisation is a key step process in the
to satisfy the new requirements of ‘design for additive
manufacture of 3D parts, ensuring material usage within a
manufacturing’ (DfAM) rules and guidelines. Dassault
defined space is fully optimised. Dassault Systèmes’ CATIA
Systèmes, a world-leading provider of 3D design software,
applications for generative design provide product modelling
3D Digital Mock Up and Product Lifecycle Management
powered by the 3DEXPERIENCE platform.
(PLM) solutions, collaborated with Renishaw to streamline its
3DEXPERIENCE® platform to deliver a no-compromise end-
to-end AM design experience.

Like Renishaw, Dassault Systèmes is committed to providing solutions which simplify the integration of
3D design and printing technology into all manner of production environments. This common thinking was
instrumental in the project’s success. Dassault Systèmes provides the functional generative design and
physics-backed manufacturing simulations which are a key part of the metal 3D printing process chain.
Dassault Systèmes (USA)
Dassault Systèmes’ companion DELMIA software application More specifically, the project ultimately aimed to remove any
then enables users to design and test a product in a simulated need for the export of native CAD source files in a universal
production environment. Importantly, the software manages .STL triangulated file format – an export long proven to
product build set-up and the generation of laser (scan) tool introduce manufacturing errors and a prime cause of loss of
paths required by the AM systems. quality control in successive product versioning.

Simulation of the complete AM build process, including full


product stress analysis and distortion prediction, is carried out Solution
using the 3DEXPERIENCE platform’s simulation application. Using 3D design innovations in the automotive industry
In its close collaboration with Dassault Systèmes, Renishaw as a demonstration and test mechanism, this software
employed a broad range of its state of the art precision enhancement project was based around the design and
manufacturing and metrology products. These included manufacture of a futuristic door hinge for Dassault Systèmes
the flagship RenAM 500M metal additive manufacturing concept car, Bleu.
systems with laser powder bed fusion technology, QuantAM A complex, lightweight, double-wishbone type component, the
build preparation software, machine tool probing systems, hinge presented Dassault Systèmes and Renishaw engineers
EquatorTM gauging systems and CMM with REVO 5-axis with an authentic production scenario demanding close
measurement system. attention to structural optimisation, multi-material design and
Renishaw applied its technologies for characterisation of part consolidation.
the build process, design validation and automated process Working within the 3DEXPERIENCE platform, a radical 3D
control of a final subtractive machining operation. These, hinge design was produced using the CATIA generative
combined with the 3DEXPERIENCE platform’s applications, design capabilities. Associated tool paths generated by
delivered a seamless AM process and the end-to-end DELMIA applications were imported into QuantAM for
manufacturing solution required. additional processing prior to output to the RenAM 500M
system.
Challenge Following an iterative, closed-loop sequence of hinge design
The key challenge faced by Dassault Systèmes and Renishaw adjustment, simulation, printing and precision inspection, the
engineers was to achieve alignment of their respective virtual specific AM build rules that needed to be integrated within the
and real worlds - of 3D design, test and analysis software and 3DEXPERIENCE platform’s software to achieve optimal 3D
metal 3D printing. Software needed to follow real AM build design and printing were determined.
rules.
Renishaw made an application programming interface (API)
The collaboration aimed to rationalise the AM design and for its QuantAM software available to Dassault Systèmes for
manufacturing process so manufactures can move away from integration within the DELMIA application for the generation of
an expensive ‘design – build – test’ approach to a ‘right-first- right-first-time 3D printing tool paths.
time’ approach.

Figure 1: Bleu car hinge component in CATIA


Figure 2: Bleu car hinge component in QuantAM build preparation software

Results Subham Sett, Director of Additive Manufacturing and


Materials, SIMULIA, Dassault Systèmes, commented, “Like
As a direct result of the collaboration between Dassault Renishaw, Dassault Systèmes is committed to providing
Systèmes and Renishaw, 3DEXPERIENCE platform users solutions which simplify the integration of 3D design
can now print directly to the complete range of Renishaw AM and printing technology into all manner of production
systems from within the existing native CAD environment. environments. This common thinking was instrumental in the
There is no need to export data files to an external system for project’s success. Dassault Systèmes provides the functional
additional post-processing. generative design and physics-backed manufacturing
The enhanced CATIA, SIMULIA and DELMIA applications simulations which are a key part of the metal 3D printing
mean that innovative 3D product designs are now process chain.”
automatically optimised for both manufacture on Renishaw AM
systems, and end functional performance. As a result, parts
are produced more accurately from the outset, bringing lead
time and material cost savings.

The focus of attention for the 3D design software


developments and the ultimate by-product of the project, the
conceptual hinge for the ‘Bleu’ concept car, also provided
further real-world evidence of the benefits to be achieved by
3D design and printing.

The evolution of the component design is shown most


dramatically in Figure 1 and Figure 2, where the original
CATIA product design can be compared with the final product
tool path generated in QuantAM. The finished aluminium
printed part is itself shown in Figure 3 and 4.

While in this case the original and optimised part volumes


were virtually identical, all of the support structures were
removed from the hinge design, creating a more elegant, Figure 3: Bleu car hinge component being measured on a Renishaw
more reliable and yet far simpler automotive product. EquatorTM gauging system
Figure 4: Bleu car hinge component in RenAM 500M build chamber

For more information visit www.renishaw.com/dassaultsystemes

Renishaw plc T +44 (0) 1453 524524


F +44 (0) 1453 524901
New Mills, Wotton-under-Edge
E [email protected]
Gloucestershire, GL12 8JR
United Kingdom www.renishaw.com

For worldwide contact details, visit www.renishaw.com/contact

RENISHAW HAS MADE CONSIDERABLE EFFORTS TO ENSURE THE CONTENT OF THIS DOCUMENT IS CORRECT AT THE DATE OF

*H-5650-3375-01*
PUBLICATION BUT MAKES NO WARRANTIES OR REPRESENTATIONS REGARDING THE CONTENT. RENISHAW EXCLUDES LIABILITY,
HOWSOEVER ARISING, FOR ANY INACCURACIES IN THIS DOCUMENT.

© 2017 Renishaw plc. All rights reserved.


Renishaw reserves the right to change specifications without notice.
RENISHAW and the probe symbol used in the RENISHAW logo are registered trade marks of Renishaw plc in the United Kingdom and other countries.
apply innovation and names and designations of other Renishaw products and technologies are trade marks of Renishaw plc or its subsidiaries. Part no.: H-5650-3375-01-A
All other brand names and product names used in this document are trade names, trade marks or registered trade marks of their respective owners. Issued: 05.2017

You might also like