Computer-aided simulation of additive manufacturing processes

1. A method performed by a data processing system to design and manufacture a part while accounting for deformities caused by heat and structural load effects, comprising:

receiving a finite element (FE) model of a part to be manufactured;

for each of a plurality of layers:

intersecting a depositing layer line with the FE model to define an FE layer mesh that represents a manufacturing layer for the corresponding layer;

simulating manufacture of the FE layer mesh for the corresponding layer;

during the simulated manufacture, evaluating distortions to each FE layer mesh caused by heat and structural load effects, and evaluating effects of adding different heat sink configurations to identify a design that minimizes warping of the part; and

modifying the FE model according to the distortions caused by heat and structural load effects during the simulated manufacture and according to the identified design that minimizes warping of the part; and

manufacturing the part according to the modified FE model, including the distortions caused by heat and structural load effects.

2. The method of claim 1 , wherein simulating manufacture of each FE layer mesh includes applying simulation parameters to the FE layer mesh, including applying a heat load to the FE layer mesh according to thermal response data.

3. The method of claim 1 , wherein simulating manufacture of each FE layer mesh includes applying simulation parameters to the FE layer mesh, including performing a nonlinear transient heat transfer analysis of the FE model including structural load information.

4. The method of claim 1 , wherein simulating manufacture of each FE layer mesh includes deforming FE node point locations of the FE layer mesh according to applied simulation parameters.

5. The method of claim 1 , wherein receiving the FE model includes creating the FE model from a solid model.

6. The method of claim 1 , wherein simulating manufacture of each FE layer mesh includes applying structural loads to the entire FE model.

7. A data processing system configured to design and manufacture a part while accounting for deformities caused by heat and structural load effects, comprising:

a processor; and

an accessible memory, the data processing system particularly configured to receive a finite element (FE) model of a part to be manufactured;

for each of a plurality of layers:

intersect a depositing layer line with the FE model to define an FE layer mesh that represents a manufacturing layer for the corresponding layer;

simulate manufacture of the FE layer mesh for the corresponding layer;

during the simulated manufacture, evaluate distortions to each FE layer mesh caused by heat and structural load effects, and evaluate effects of adding different heat sink configurations to identify a design that minimizes warping of the part; and

modify the FE model according to the distortions caused by heat and structural load effects during the simulated manufacture and according to the identified design that minimizes warping of the part; and

control the manufacture of the part according to the modified FE model, including the distortions caused by heat and structural load effects.

8. The data processing system of claim 7 , wherein simulating manufacture of each FE layer mesh includes applying simulation parameters to the FE layer mesh, including applying a heat load to the FE layer mesh according to thermal response data.

9. The data processing system of claim 7 , wherein simulating manufacture of each FE layer mesh includes applying simulation parameters to the FE layer mesh, including performing a nonlinear transient heat transfer analysis of the FE model including structural load information.

10. The data processing system of claim 7 , wherein simulating manufacture of each FE layer mesh includes deforming FE node point locations of the FE layer mesh according to applied simulation parameters.

11. The data processing system of claim 7 , wherein receiving the FE model includes creating the FE model from a solid model.

12. The data processing system of claim 7 , wherein simulating manufacture of each FE layer mesh includes applying structural loads to the entire FE model.

13. A non-transitory computer-readable medium encoded with executable instructions that, when executed, cause one or more data processing systems to:

receive a finite element (FE) model of a part to be manufactured;

for each of a plurality of layers:

intersect a depositing layer line with the FE model to define an FE layer mesh that represents a manufacturing layer for the corresponding layer;

simulate manufacture of the FE layer mesh for the corresponding layer;

during the simulated manufacture, evaluate distortions to each FE layer mesh caused by heat and structural load effects, and evaluate effects of adding different heat sink configurations to identify a design that minimizes warping of the part; and

modify the FE model according to the distortions caused by heat and structural load effects during the simulated manufacture and according to the identified design that minimizes warping of the part; and

control the manufacture of the part according to the modified FE model, including the distortions caused by heat and structural load effects.

14. The computer-readable medium of claim 13 , wherein simulating manufacture of each FE layer mesh includes applying simulation parameters to the FE layer mesh, including applying a heat load to the FE layer mesh according to thermal response data.

15. The computer-readable medium of claim 13 , wherein simulating manufacture of each FE layer mesh includes applying simulation parameters to the FE layer mesh, including performing a nonlinear transient heat transfer analysis of the FE model including structural load information.

16. The computer-readable medium of claim 13 , wherein simulating manufacture of each FE layer mesh includes deforming FE node point locations of the FE layer mesh according to applied simulation parameters.

17. The computer-readable medium of claim 13 , wherein simulating manufacture of each FE layer mesh includes applying structural loads to the entire FE model.