AM Modeler Plugin

[ZohrehA]

Hi,
I would like to model cold spray process (a coating process but also use for additive manufacturing) with AM modeler.

I am new at AM Modeler plugin, till now I was successful to create an event series for heat source.

But for adding material I have problem from the beginning. I found that I have to use Progressive Element Activation but I don’t know where or in which module I can define it? I either don’t know if I need subroutine for defining material addition or not?

In this stage I am not going to consider material property changes with temperature.

My model is a simple model: a flat rectangle part, with the initial room temperature. The maximum temperature that part reach during the process is about 300 ̊C (below melting point).
The heat source is a high pressure, high temperature Ni gas (P= 30 bar, T= 500 ̊C) that carries high velocity particle (about 800 to 1200 mm/s) through a de Laval nozzle. The nozzle travel above the surface and spray the high velocity high temperature particles on the surface. So the particles attach to the surface by their kinetic and thermal energy. The convection and radiation is considered. And only elastic property is define for material.

I have studied a lot of documents and ABAQUS documentation, but it is not clear for me that what is the first step and where and how I can define the Progressive Element Activation

Is anyone here that could help me in this regard?

 

[ZohrehA]

Ok, yes I got what you mean.
I fixed it.
But the previous problem of temperature not changing is still remain. I mean even with heat flux of 90e9 w/sm3, the temperature of coating and substrate don't go up. It remain at 32 degree (the initial temperature).
I deactivated convection, radiation and load module in normal model and they are only defined in AM Plugin.
This problem is really bothering, I cannot find the reason!
I really appreciate if you can help me about it.

 

[FEA way]

If you share the .inp or .cae file, I will take a look at this and try to find the source of the problem.

 

[ZohrehA]

Hi;
Thank you so much. The .inp file is attached. Unfortunately uploading the .cae file accurse with an error
I really appreciate it.

 

[ZohrehA]

Please let me know if you need any infos.

 

[ZohrehA]

Dear FEA way,

Could you open the .inp file? Since my ABAQUS version is 2022 I want to know if it is OK for you or not?

 

[FEA way]

I can check the input file but it would be much easier with the .cae file. Maybe you could pack it to .zip or use some hosting website to share it here.

 

[hadip]

Dear Zohreh,
I see you are working with the Abaqus ADM modeler plugin,
I'm trying to use it for FDM process,
can I ask you where I can find some tutorials for it?
thank you very much.

 

[ZohrehA]

Dear hadip,

Sorry I was long time away.
You can use ABAQUS documentation. It explained completely.
For FDM You can read:

Abaqus => Analysis => Analysis Techniques => Additive Manufacturing Process Simulation => Special-Purpose Techniques for Additive Manufacturing => Thermomechanical Analysis of FDM- and LDED-Type Additive Manufacturing Processes

 

[ZohrehA]

Dear FEA way,

Sorry, I was long time away.
I Zipped and uploaded it.
Thank you in advance for your time.

 

[ZohrehA]

Dear FEA way,

Here is also .jnl file. In case is needed.

 

[AutoAA]

Dear FEA way,

If you could help me, I would like to mention one of the issues I am having regarding AM Modeller plug-in. Currently, I am doing a simulation for additive manufacturing of Ti-6Al-4V. If I use lower laser power of 5000 (5W), the simulation run fine. But, the problem is when I use laser power of 200W. It says zero heat flux everywhere and heat flux equilibrium is not achieved within tolerance. It took a long time to activate the material bead progressively after the first activation of the material bead. Thanks

 

[FEA way]

@ZohrehA Exactly which version of Abaqus are you using ? Is it 2022 golden or with some fix packs ? I can't open the AM Model section in your .cae file.

@AutoAA It's hard to say what's going on without seeing the model. Are there any additional warning or error messages ? At what point in the analysis does the solver stop ?

 

[ZohrehA]

Dear FEAway,

Yes, I am using ABAQUS 2022 golden. But I changes the AM Modeller plug-in to AM Modeller plug-in 2018 (because the AM Plug in of 2022 was difficult to understand).

 

[FEA way]

That would explain it. It’s better to stick to one version of Abaqus (possibly the newest one - fewer bugs) because of the significant differences between them. AM process simulations are a new feature and each version (or even fix pack) brings lots of changes.

 

[ZohrehA]

Yes, but I was not able to use AM Plug-in 2022. It was the reason that I replaced it with 2018.
Do you think it is the reason that the temperature of the model is not raising up?!!

 

[FEA way]

Unfortunately, the workflow is different than in the previous versions in the case of which the plug-in had to be downloaded and installed. I would try from scratch in the newest version that you can use (maybe even 2023 if you have access to it). There’s a significant chance that it will start working then. Unless there’s some mistake in your assumptions or setup.