Efficient Prediction of Thermal Stresses and Distortion in Complex Optimized Missile Structures

Additive manufacturing (AM) technology offers the potential to fabricate complex geometries that cannot be realized using conventional subtractive methods.In current industrial AM processes, support structure is typically needed for complex geometries that contain overhangs.Determination of the type and distribution of support structure is often based solely on technician experience.This process is far from optimal and does not take into account thermally-induced residual stress buildup and subsequent part distortion that can occur when the support material is removed.Hence significant non-recurring engineering costs are incurred to develop a repeatable AM fabrication process for production.Currently, a computational tool that is capable of optimizing the support structure design to minimize thermally-induced residual stress or distortion does not exist.The key challenge to the development of an efficient topology optimization tool for support structures is the lack of an ultra-fast method for predicting residual stress and distortion in an AM part.Materials Sciences Corporation with team with the University of Pittsburgh to develop a computational tool cable of simulating the residual stress and distortion of a realistic AM part in minutes for use in developing optimal support structure by employing a numerically efficient finite element (FE) based process simulation model.