WEB Microstructural Simulation of additively manufactured Structures
Additive manufacturing offers a wide range of geometrical design options. Filigree features (e.g. lattice structures) can be printed as well as complex organic geometries resulting e.g. from bionic shape optimization. Inherent with this manufacturing process and hardly avoidable are a certain amount of micro-porosity and pronounced surface roughness. In a detailed and comprehensive structural simulation every of the above mentioned geometrical characteristics needs to be included in the simulation model.
Detailed 3D geometrical information on the manufactured part can be obtained by means of Computed Tomography (CT). With this nondestructive inspection method external as well as internal surfaces can be determined with high precision. To build an FE mesh without loss of complex geometrical information is a challenging task when using a classical Finite Element Method since there is the need to create a geometry conform mesh. Immersed Boundary Finite Element Methods offer a feasible alternative to overcome this meshing problem. No geometry conform mesh generation is necessary and the exact surfaces measured by CT and determined with an appropriate sub-voxel precise surface determination algorithm can be used for the structural simulation.
An immersed boundary Finite Element method will be presented that in conjunction with CT measurement enables to include geometrical features very accurately into a Finite Element Simulation and thus to calculate stress concentrations resulting from small geometrical features as well as numerous internal and external defects. This method is used to calculate stress concentrations in additively manufactured structures. It is also applied to derive homogenized material properties for material probes with complex internal geometrical features.