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Abaqus AM

Abaqus AM

Abaqus AM

(OP)
Hello,

I was trying to simulate the progressive element activation in a cylinder. Would anyone suggest to me how to generate an event series for the addition of material in cylindrical coordinate?

RE: Abaqus AM

Event series must be defined in a global (rectangular) coordinate system. You can convert g-codes obtained in CAD software to event series data using a Python script.

RE: Abaqus AM

(OP)
Thank you very much FEA way. I am not good enough in python programming, Would you mind if you help me in writing a program that can generate event series.inp file from a G-code, please? We may also set some form of academic collaboration so that we can publish the research output together. What would you suggest FEA way?

RE: Abaqus AM

There's already a script like that to convert g-code from ReplicatorG to event series data. The script is named "generateEventSeries.py" and can be downloaded from Dassault Systemes Knowledge Base. It may not be available to users without a customer account though.

RE: Abaqus AM

(OP)
Thank you very much FEA way, I will look for it then. Once I found, I will try it and get back to you if I face difficulties.

RE: Abaqus AM

(OP)
Dear FEA way

I got all the required script files. I tried with the G-code file available with the files and it works well. As I understood the G code was generated with replicatorG software which is not available by now I think. I generated the G-code for my part using Ultimaker Cura software and I tried to use the scripts that I download from the Dassault Systems Knowledge Base but it is not working for me. It pops up an error message that states the G-code file is not found as expected. I tried to debug the G-Code reader.py and generateEventSeries.py files but I couldn't fix it. Would you help me in modifying the G-code or the scripts, please? Here below I have attached the files I used.
I highly appreciate your support.



RE: Abaqus AM

ReplicatorG has not been updated for a long time, but its files are still available and it should work normally. The generateEventSeries.py script was designed specifically for use with this software. In order to generate event series from g-codes created by other CAM programs, you would need to modify the script, as you say.

RE: Abaqus AM

(OP)
Thank you very much. Modifying the script has become difficult for me. Is there any other method you are aware of which can be used to generate event series to build a simple cylinder?

RE: Abaqus AM

(OP)
Hey FEA way,

I generated the event series with excel and it is working for me now. But, I got thins warning messages while the analysis is running.

Output variables filmcoef and sinktemp are not supported for output with load label ffs and ffsnu.

Output variables filmcoef and sinktemp are not supported for output with load label ffs and ffsnu.

What would be the source of the problem?

RE: Abaqus AM

These warnings can be ignored, unless you need the output variables mentioned by them but I don’t think that’s the case.

RE: Abaqus AM

(OP)
Dear FEA way,

Thank you very much, actually the convective and radiative heat losses are one of the output variables that I am looking for.

RE: Abaqus AM

Check other available output variables in the documentation, I think that you will be able to find ones that describe the proper aspect of your model (for example various heat flux variables). The outputs that you chose so far are quite specific and limited to rare cases.

RE: Abaqus AM

(OP)
Dear FEA way,

Thank you very much. I will get back to you.

RE: Abaqus AM

(OP)
Dear FEA way,

I was trying to integrate a DLOAD subroutine with AM model by just adding the DLOAD FORTRAN file into a job for structural analysis but the simulation is just jumping from the beginning to end without simulating the moving load. Is it normally possible to integrate a separate DLOAD subroutine with AM Model this way?

RE: Abaqus AM

You have to reference this subroutine in distributed load definition (*DLOAD) by specifying the proper load type label. Check the documentation for the DLOAD subroutine and examples of its usage.

RE: Abaqus AM

(OP)

Dear FEA way,
Greetings, I was running a sequential thermal-structural AM problem and it prompted the following error message.

UEPActivationVol: Unknown jPtkEvtType 2 or jPtkAlgo 1 for MaterialPath

I couldn't figure out the cause. Would you help me please?

RE: Abaqus AM

Check the definition of material input in your model, it might be incorrect. Make sure that it uses proper event series.

RE: Abaqus AM

(OP)
Dear FEA way

Greetings, I am able to simulate the progressive buildup of a cylinder. The width of the material added at a time is 300mm, and I want to apply the heat source uniformly across the layer width, but as you can see in the simulation video attached, the AM modeler only applies the heat on the edge of the layer. Is there a method that you can propose to fix this problem, please?

RE: Abaqus AM

Have you tried to visualize toolpaths in AM Modeler plug-in ? This can help you identify the source of the problem.

Can you share the details of this simulation and possibly input files ?

RE: Abaqus AM

(OP)
Dear FEA Way,

Thank you for your reply. Yes, I have visualized the plot of the toolpath, but it doesn't have information about the heat source. Here I have attached the .inp file, but I couldn't attach the whole file because the file size is a bit bigger than 200MB. Should I send it to you by mail?

RE: Abaqus AM

The cylinder is very thin and meshed with just one layer of elements in the through-thickness direction. This makes it difficult to obtain good results. You could try increasing the size of the box for the uniform heat source, maybe also positioning the path differently (for example, slightly above the model and corrected with proper offset or box size values). Check different types of heat sources as well.

How have you eventually managed to prepare the path for the event series in this case ? Manually or with the help of some g-code generator ?

RE: Abaqus AM

(OP)
Dear FEA way,
Thank you for your reply. I will try and get back to you. I used Excel to generate the event series.

RE: Abaqus AM

I tried all the tips that were offered here and I still managed to get the desired result. Although it was a bit difficult, it still does not compare to how I wrote an admissions essay at university. I had no idea it would be such a challenge when I saw what was needed. But then the guide https://studymoose.com/university/wake-forest-university helped me and there was even an example. So for me it was much more complicated than setting up a program and writing a script in python, that's how I am. I don't really like to write.

RE: Abaqus AM

(OP)
Dear FEA way,

Greetings, I was trying to simulate the progressive buildup of a simple rectangular bar using the AM module of Abaqus 2022 and I got the following error message when I tried to submit the job:
"the region selected for the following element progressive activations contains invalid geometry or mesh components"

What would be the problem?


Regards,

Kasahun

RE: Abaqus AM

It's hard to say without the file. Maybe element type not supported by AM features is used. Also, make sure that you select only the region of the model which is supposed to be printed.

RE: Abaqus AM

Dear Kasmat2013,

Thank you for your useful information. Can you give more information about the generation of event series from G-code using Excel? Is it possible to share your Excel file?

Thank you

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