Simulating Reality 3D Print with FEA

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Simulating Reality with FEA
Finite element modelling in many ways is more like an art than a science since the
quality of the results is dependent upon the quality of your model. One of the more
common errors that a beginning finite element analyst makes in modelling is to
simply simulate the geometry rather than to simulate both the geometry and the
physical behaviour of the real structure. The following modelling guidelines are
provided to put a little more science back into the art of finite element modelling:
About the speaker
Learning objectives
• Creating simulations.
• Assigning Materials.
• Settings constraints and
loads.
• Interpreting simulation
results.
Disclaimer
This class is designed to familiarise you with some of the Simulation tools. it is not a
replacement for a solid understanding of Finite element fundamentals.

The principles of logic, physics and good engineering ALWAYS apply.

Be careful when creating Simulations, they can be subjective and poorly defined
simulations will result in poor simulations!
What are we covering in this session?
Lead Screw Motion Joint
• Reduce Print Time

• Reduce cost

• Consider materials usage

• Consider alternative materials

Original design considerations
• Materials

• Hand Calculations

• Inventor Models
Selection of material
Polystyrene Acrylonitrile butadiene styrene
• Hard wearing • Cost effective
• High thermal resistance • Quicker print time
What is a Mesh

Sources: http://www.math.bas.bg/~nkirov/umg/fig3.gi
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http://people.sc.fsu.edu/~jburkardt/m_src/distmesh_3d/p02.pn
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Creating a Simulation: Inputs
Every simulation needs 3 key inputs:
• Materials.
• Constrains.
• Loads.

Sequence for input

Materials

• Materials for the Simulation can be different to the Material in the model.
Constraint – Definitions:

*Note that the Frictionless constraint can be used to simulate symmetry.

Loads – Definitions:
Creating a Simulation: Mesh Settings
Interpreting your results:
• Are the results what I expected?
• What does the Actual Deformation look like?
• Where are the High Stresses?
• Is there a possibility of Singularities?
• What does the Convergence plot look like?
Convergence
Singularities
• FEA uses the Theory of Elasticity: Stress = force/area.
• No Matter how much we refine the Mesh, the area will remain 0.
•If the area is 0 then Stress = Infinite.
•
Creating a simulation:
Apply Constrains
Apply Load
Shape Optimisation
Joint Analysis
Joint Report
Joint 1 Joint 2

Comparison
Joint 1 Joint 2
Print Time = 30min Print Time = 19min
Filament Use= Filament Use=
3405mm 2575mm