In the previous post, we have shown that ReveaL is competitive with respect to currently available commercial codes. But this study was performed on a relatively simple geometry with a straightforward workflow. If a design is created in a standard CAD preprocessing tool and the simulation runs directly on it, mesh generation usually works smoothly without any issues.

Well… But one department was transferring the design to another department. It was re-saved, re-converted… And you, an engineer, received yet another geometry and started preparing the simulation… And then, you see this:

Really? Is it not familiar? Well, I have seen it a couple of times. After looking at it and looking for a problem, one decides just to redraw the geometry… For a simple geometry, this would take 20-30 minutes.

But what if you can do it in one click? ReveaL can handle broken geometries in precisely the same way as conventional designs!

Let’s take it to the extreme and randomly displace every vertex of the sandwich structure from the previous post and make out of a very smooth geometry an absolute nightmare for an engineer:

At the right, there is the same geometry as at the left, just absolutely non-watertight. In practice, flawed geometries contain defects at a couple of spots, causing meshing troubles. In contrast, this model is full of defects. But well let’s give it a go!

In ReveaL, the user should input the same “elements” as for the smooth, or as we say set discretization control, set the material parameters, specify geometry… And, it is ready to go!

SImulation setup in ReveaL

After exactly 11 seconds (!), ReveaL is ready to show the results. And what do we get?

The maximum displacement value for the watertight geometry is 90.42mu while for the broken one – 90.09mu. There is no difference! And stresses?

The maximum von Mises stress is 616.17MPa for the watertight and 627.63 MPa for the flawed geometry. Less than 2% difference!

Isn’t it already a big step? The first and most important result is that we can simulate these geometries at all. With no manual effort and no extra steps: just click “Submit”. And secondly, both displacements and von Mises stresses almost show no difference!

Impressive? Request your free trial and use ReveaL directly in your browser!

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The engineering community is a tough cookie. And, if anyone tells you otherwise, don’t believe it. The hard truth is that engineers like to pose questions. And, rightfully so: this is how they find solutions to the most sophisticated problems. Without this mindset, there won’t be a breakthrough in industrial development, disruptive changes in the existing processes, or simply better solutions. I am an engineer myself. And I sincerely understand the necessity of these questions. So, today I would like to answer one of them.

Can our software, ReveaL, compete with existing commercial solutions? We heard many times that our solution solves a lot of engineering pain for cases where the available model is non-watertight or exists only in a form of a computed tomography recording. But, can ReveaL deliver the same results for a standard use case while keeping up with the performance? Well, let’s give it a go. Let’s challenge ReveaL in accuracy, time and memory.

Challenge of lattice structures

In a frame of a pilot project with Siemens, we were confronted with the following challenge. We were offered to take a simple use case in industrial 3D printing: a sandwich structure with lattice between two plates. When we increase the size of this structure, a conventional FEM solver starts being more expensive in terms of meshing and solving times.

Case 1: BCC with 2x2x1 unit cells
Case 2: BCC with 4x4x2 unit cells
Case 3: BCC with 6x6x3 unit cells
Case 4: BCC with 8x8x4 unit cells

 

Our partner at Siemens simulated these lattices under torque using their conventional commercial software while we provided them with the results of ReveaL. We agreed on comparing four main quantities: average stress arising in one diagonal strut, average stress in the whole lattice, simulation time and peak memory. Similar workstations, same setup – same challenge.

…Drumroll…

ReveaL is a competitive software!

“Eh?! How is it possible?” – would you ask, – “The software is so young!” Yes, we are a young startup, but our technology is mature.

Let’s look at the numbers. For a medium size of the lattice Reveal showed the following results:

Case 3, quadratic elementsCommercial softwareReveaL
Degrees of freedom4.9 Million4.84 Million
Wall clock time (run time)532 s583 s
Maximum memory41.8 Gb64.8 Gb
Corner distortion86 µm92 µm
Average stress in a diagonal strut107 MPa109.5 MPa
Average stress in the lattice141 MPa144.9 MPa

Looks promising? Yes! And this is just the tip of the iceberg, you can read more details about this use case in our whitepaper:

What is in it for you?

Of course, we have still a lot to improve, a lot of features to build. But we can say already now that ReveaL is a simulation tool which is fast, reliable and accessible. The outstanding advantage of using ReveaL to perform simulation is that it works for any type of geometrical models: non-watertight CAD, point clouds or CT scans. It is agnostic to the input geometry and its quality. This allows to reduce computational costs, remove manual effort and explore designs that were never feasible for simulations before.

We at DirectFEM do not provide yet another STL repair tool, we offer a standalone software, ReveaL, that allows to simulate directly on the provided geometry removing the step of geometry reconstruction and healing. And, as you see, for a standard case, ReveaL performs at least as good as commercial tools or even better.

Do you want to try?