Metal Additive Manufacturing Conference 2018

Due to the progressive development of additive production, it is increasingly possible to manufacture metallic components with free-form geometry or filigree lightweight structures in small numbers. Because of this partly complex geometry, the production simulation and the calculation of the building parts are particularly difficult. In addition, these processes are carried out very close to production process if they are applied at all. Recently, various software tools have been developed to carry out a process simulation for additive manufacturing. These systems differ both with regard to the calculation approach (Inherent strain method, Transient calculation) as well as in the scope of functions (e.g. building orientation, support generation). In the paper, these tools are first analyzed with regard to the functional scope. A comparison and evaluation of the tools are then carried out using selected criteria. For this purpose, special benchmark components were developed, which are presented in the paper. Furthermore, simulation studies with corresponding parameter variation and the comparison of the simulation results with real manufactured components are presented. As a result, possible existing deficits of the simulation tools are derived in the context of the currently practiced process chain. In this regard, requirements for the further development of the simulation tools as well as a possible modification of the current process chain are discussed. The interfaces to established software tools such as Materialise Magics or current CAD systems are also taken into account to obtain for example conclusions for the design of a part or the production planning.