Abaqus AM Modeler - troubles with workshop 1

[owner21]

Hello, everyone!

I recently have downloaded Abaqus AM Modeler plugin and I was trying to go through workshop named "LDED_ThinWall". Everything was OK until I got some embarrassing results of the simulation. Maybe somebody could help me to figure out is it a modeling mistake, plugin bug or just my inattentiveness?

So the problem description:
It is a simulation of thin-wall tube which is printing by Laser Direct Energy Deposition method with material deposition and laser-path event series included in the model. After successful completion of two sequential jobs I was checking thermal and structural results and I saw that one wall doesn't get heat at all, it stays with initial temperature of 300 K, so it has most displacement and stresses.

The question is: what's wrong with workshop model or where should I make changes to make temperature distribution more uniform among all walls?

Please see attached image with results.

 

[FEA way]

Check the toolpath definitions (you can visualize them in AM Modeler) and make sure that step time is correct. See how element status, temperature and heat flux change during the analysis. And finally, make sure that radiation and convection are applied to the whole model.

When working with AM Modeler it’s often necessary to check input file as some keywords may be generated incorrectly.

 

[owner21]

FEA way, thanks for a quick reply!

I think that toolpath definitions are quite correct, because I have visualized path in AM Modeler and saw nothing wrong. Also temperature and heat flux are changing so that it still seems that one wall doesn't get heat. Radiation and convection are applied to the whole model too. It would be great if you could take a quick look inside of this model, I've attached it to this message.

I made some changes in heat transfer step definition to see more clearly what is going on.

 

[Chandra281]

How you are generating
T,x,y,z,p
For input. If you have any code related to it can you share it.

 

[FEA way]

To create paths for AM Modeler you can use some CAM software with G-code generator. Simulia recommends these open-source programs: Slic3r, ReplicatorG. But of course there are more possibilities.

 

[Chandra281]

Slic3r is open source it's okay but it generate g code for fdm process where the file did not contain in the format required for abaqus AM modeler.

 

[Chandra281]

Or any one doing it from MATLAB code?

 

[FEA way]

There is a way to convert g-code generated by ReplicatorG into format used by Abaqus. To do it you need a script named generateEventSeries.py. It can be found among the files downloaded with AM plug-in.

 

[owner21]

Chandra281, I was generating Event Series by hand calculations in Excel because my geometry was quite simple.

I know that ReplicatorG could help me, but I've met some compatibility difficulties and did not handle them.

FEA way, I would be much obliged if you could share some more detailed instructions of how-to-use it.

 

[FEA way]

To use the script after downloading it, open command window and type:
abaqus python generateEventSeries.py g-code_file_name roller_pad_dimension delay_between_layers power

where: roller_pad_dimension - extent to which the roller startong point and end point are extended from min Y and max Y coordinate of the model for each layer (value between 0 and 1), delay_between_layers - time taken for the roller to deposit material

You can find a detailed description in the Knowledge Base article "Abaqus/CAE Plug-in Utility for Additive Manufacturing Process Simulation".

 

[owner21]

FEA way, thanks, but I must have put it wrong in my previous message. I would like to find instructions for ReplicatorG in conjunction with Abaqus. The best option would be to see the certain case of their work together, but I don't really hope to see it, actually.

 

[Jazzy220]

Hi,
@owner21 and FEA Way, could you please share the files here to convert g-codes into eventseries? mean I didn't found a right file yet to do this and if there is any tutorial or guidelines please do share.

Thanks in advance!

 

[FEA way]

The script named generateEventSeries.py along with examples and instruction can be found in Dassault Systemes Knowledge Base article "Abaqus/CAE Plug-in Utility for Additive Manufacturing Process Simulation". You just need a 3ds account to access it.

 

[Jazzy220]

Hi,
FEA WAY, I have tried but not found the plugin Utility you mentioned, following is the link I used:

https://help.3ds.com/2020/english/D...e=all&id=ed7f2f13e5d048d4b435182ac167cda6#Pg0

Thanks if you have link to share.

 

[TarekMst]

Hello,
FEA way I have download generateEventSeries.py file and when I use it in cmd, an error come up "importError: No module named GcodeReader" how to solve it, I have searched the web for import GcodeReader and did not find anything ? how to use this file?
Thank you,