best welded
Welding structure simulation
Simufact.welding 3.1
What is Simufact.welding?
Virtual process design
Temperature distribution in components and heat
transfer into clampings
Prediction of welding distortions and
residual stress during welding and after
releasing tools
Simulation of local material properties
(e.g. flow stresses or phase fractions) Simufact.welding is directed to welding
Graphical presentation and export
of tracking points
Simulation of process chain and
further mechanical analysis
Simufact.welding
Slide 2
specialists in research, development and
manufacturing.
There is no need to be a specialist for
computer aided calculation methods.
What can Simufact.welding offer?
Virtual process design of welding processes including tacking, fixing concept and
pre-heating
Simufact.welding
Slide 3
What can Simufact.welding offer?
Virtual process design of welding processes including tacking, fixing concept and
pre-heating
Simufact.welding
Slide 4
What can Simufact.welding offer?
Temperature distribution in components and heat transfer into clamping tools
Simufact.welding
Slide 5
What can Simufact.welding offer?
Prediction of distortions during and after clamping and prediction of residual
stresses due to welding
Simufact.welding
Slide 6
What can Simufact.welding offer?
Fast process variations by copy function
For instance minimization of distortions via varying the clamping conditions
Simufact.welding
Slide 7
What can Simufact.welding offer?
Automatical real simulation of possible gap formation during welding by high
resolution contact between components
Gap ?
F?
F?
F?
F?
Simufact.welding
Slide 8
What can Simufact.welding offer?
Simulation of local material properties e.g. changed flow stresses of phase
fractions
Simufact.welding
Slide 9
What can Simufact.welding offer?
Graphical presentation and export of tracking points
Simufact.welding
Slide 10
How does Simufact.welding works?
Geometry and meshing
Weld paths and fillermaterial
Mechanical and thermal boundary
conditions
Heat source modeling
Time management
Prediction of local material properties
Postprocessing
Simufact.welding
Slide 11
Geometry and meshing
Finite element meshes can be imported from a Nastran-bulk-file (*.bdf)
Automatic mesh refinement during welding for high thermal gradients
Simufact.welding
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Weldpath and fillermaterial
Easy definition of weld paths via node picking or by import of a csv-file
with path coordinates
Automatic generation of a FE-mesh for filler material
Simufact.welding
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Mechanical boundary conditions
Automatic generation of clamping geometries
Adjustable clamping times
Contact between components
and filler materials
Contact between components and tools:
Spring stiffness C:
Automatic determination of the direction
rectangular to the contact surface
Initial force F:
Automatic determination of the
direction rectangular to the contact
surface
Simufact.welding
Slide 14
Therma boundary conditions
Automatic detection of free surfaces for heat dissipation
Heat flux definition on contact surfaces
Variable initial temperature for preheated work pieces
Predefined default values
Initial work-piece
temperature
Convection:
Qc = -h A (T1 - T2)
Heat transfer via surface contact and
heat transfer coeffient
QCHT = A (T1 - T2)
Emissions coeffizient :
Stefan-Boltzmann-equation:
QE = - A (T14 - T24)
(0 1)
Simufact.welding
Slide 15
Heat source models
Positioning and rotation of heat sources
Automatic projection on surface with offset function
Simufact.welding
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Heat source models
Combination of heat sources using offset function
Simufact.welding
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Time management
Simufact.welding
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Material modeling during welding
Simufact.welding includes simufact.premap modules (Nancy model)
Interface to JMatPro etc.
Austenite
austenite
whrend
during
Schweien
welding
Martensit
martensite
nach
after cooling
Abkhlen
Simufact.welding
Slide 19
Postprocessing
Simufact.welding
Slide 20
Three-point bending tests
Process chain welding forming / acc. plastic strains as an indicator for damage
Temperature distribution during welding
Acc. plastic strains during forming
Acc. plastic strains during welding
Highest level of
accumulated
plastic strains at
the weld seam
close to forming
tools
Simufact.welding
Slide 21
Deep drawing and welding
Residual stress after welding
Without forming results
With forming results
Lifting distortion of the cover on
the opposite edge
Calculated without forming results
Accumulated plastic strains after welding
Calculated with forming results
After welding the component is highly plastically deformed and under high residual
stresses which influence the stress distribution and distortions during and after welding
Simufact.welding
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Welding and deep drawing
Implementation of welding distortions into forming analysis
Temperature distribution during welding
Acc. plastic strains during welding
Simufact.welding
Slide 23
Model: Forming of tailored blanks
accumulated plastic strains after forming
Deep drawing and welding
Implementation of plastic strains and residual stresses for into welding analysis
Forming simulation including unclamping, cooling, trimming and positioning for welding can be
performed in simufact.forming
Import of formed geometry from arc-files
Import of forming results from arc-files via introducing a pre state block in the dat-file (in
simufact.welding 3.1.0 by hand)
Right mouse click Import geometries
Simufact.welding
Slide 24
Calculation quality
Determination of residual stresses are said to be a quality proof for structural
weld analysis
International Round Robin test (IIW) is used as a reference example (German
standart DIN SPEC 32534-1: Numerical welding simulation Execution and documentation)
2-Layer TIG weld
material
316LNSPH / 316L
voltage
9V
current
155 A
welding velocity
40,2 mm/min
Simufact.welding
Slide 25
distortion angle
measurement: 0.033
simulation: 0.032
Conclusion
Welding simulation can be user-friendly. Simufact.welding
offers:
a.) an automatic mesh refinement
b.) handles incompatible meshes
c.) offers a fillet generator for FE-Meshes
d.) a fast method to define weld paths and
process orientation
e.) heat source models and interfaces to
process simulations
f.) modeling of clamping tools
A fast virtual optimization of clamping conditions, tacking is
possible
A coupling of simufact.welding and simufact.premap allows a
prediction of the phase proportions during and after welding
A coupling of simufact.welding and simufact.forming allows
process-chain modeling
Simufact.welding
Slide 26
simufact engineering gmbh
Tempowerkring 3
21079 Hamburg
Tel.: 040-790 162-0
Fax: 040-790 162-22
office@simufact.de
www.simufact.de
