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    Simufact Welding - Simulating Manufacturing

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    MrLantern
    Simufact.welding software allows users to simulate virtual welding processes including: 1) Predicting temperature distributions, distortions, and residual stresses during welding and after unclamping. 2) Determining if geometrical tolerances are met and local material properties change, such as hardness or phase composition. 3) Simulating full manufacturing chains involving metal forming, welding, and structural analysis. The software provides an easy to use interface for welding engineers to optimize welding parameters, clamping conditions, and identify distortions without expertise in simulation.

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    © All Rights Reserved
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    Simufact Welding - Simulating Manufacturing

    Uploaded by

    MrLantern
    205 views20 pages
    Simufact.welding software allows users to simulate virtual welding processes including: 1) Predicting temperature distributions, distortions, and residual stresses during welding and after unclamping. 2) Determining if geometrical tolerances are met and local material properties change, such as hardness or phase composition. 3) Simulating full manufacturing chains involving metal forming, welding, and structural analysis. The software provides an easy to use interface for welding engineers to optimize welding parameters, clamping conditions, and identify distortions without expertise in simulation.

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    Simufact Welding - Simulating Manufacturing

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    Simufact.welding software allows users to simulate virtual welding processes including: 1) Predicting temperature distributions, distortions, and residual stresses during welding and after unclamping. 2) Determining if geometrical tolerances are met and local material properties change, such as hardness or phase composition. 3) Simulating full manufacturing chains involving metal forming, welding, and structural analysis. The software provides an easy to use interface for welding engineers to optimize welding parameters, clamping conditions, and identify distortions without expertise in simulation.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    205 views20 pages

    Simufact Welding - Simulating Manufacturing

    Uploaded by

    MrLantern
    Simufact.welding software allows users to simulate virtual welding processes including: 1) Predicting temperature distributions, distortions, and residual stresses during welding and after unclamping. 2) Determining if geometrical tolerances are met and local material properties change, such as hardness or phase composition. 3) Simulating full manufacturing chains involving metal forming, welding, and structural analysis. The software provides an easy to use interface for welding engineers to optimize welding parameters, clamping conditions, and identify distortions without expertise in simulation.

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    of 20

    Welding Simulations with

    Simufact.welding
    SimDay 2013 Szimulcis Konferencia

    17th October 2013, Tulip Inn Budapest Millenium


    Dr. Gabriel Mc Bain

    Virtual welding process design


    Temperature development in components and
    heat transfer into clampings
    Prediction of distortions and residual stresses
    during the welding and after unclamping
    Are geometrical tolerances met?
    Prediction of local material properties
    (e.g. hardness, yield stress, phase composition)
    Are brittle phases created?
    Through-process simulation of manufacturing
    chains metal forming welding structural
    analysis

    simufact.welding is designed for


    welding engineers in research,
    development and production who do
    not have to be experts in numerical
    simulation!

    Temperature distribution in components and heat transfer into clamping tools

    Prediction of distortions during and after clamping and prediction of residual stresses

    Minimization of distortions by varying the clamping conditions


    Positioning of the clamping devices by hand or via drag and drop

    Due to expansion of the weld zone and shrinkage of the cooling material the
    gap can change

    Gap ?

    F?
    F?

    F?
    F?

    Simulation of local material properties e.g. changed flow stresses of phase fractions

    Process chain welding forming / acc. plastic strains as an indicator for damage
    Temperature distribution during welding

    Acc. plastic strains during welding

    Acc. plastic strains during forming

    Implementation of welding distortions into forming analysis


    temperature distribution during welding

    model: forming of tailored blanks

    accumulated plastic strains during forming

    accumulated plastic strains after forming

    residual stresses after welding


    Without forming results

    With forming results

    Lifting of the cover on the opposide


    edge

    Simulated without forming results

    Accumulated plastic strains after welding

    Simulated with forming results

    Geometry and Meshing


    Weld paths and
    Fillermaterial
    Clamping- and Boundary conditions
    Heat source modeling
    Time mangement
    Prediction of local material
    properties
    Postprocessing

    Fast definition of weld paths via node selction or by import of a csv-file


    with path coordinates
    Automatic generation of a FE-mesh for filler material

    Clamping devices can be generated automatically


    Clamping duration is considered
    Contact between base and filler
    material

    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

    Positioning & orientation

    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 standard 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

    distortion angle
    measurement: 0.033
    simulation: 0.032

    measurement
    simulation
    (Simufact.welding 3.10)

    Two alternative strategies:

    W4
    W2

    W3

    W5

    W6

    W1

    A
    ?
    W1
    W10
    W4
    W5

    W2

    W8

    W6
    C3

    Process :- MAG Welding


    Filler Wire Diameter : - 0.8 mm
    (Copper Coated MS Wire)

    B
    ?

    W3

    W7

    W9

    Filler material provides contact between


    parts and is automatically added during
    the simulation of the welding process:

    Welding
    Hefting

    After cooling to room temperature

    +2.13 mm

    +1.24 mm

    Simufact.welding offers user-friendly welding


    simulation
    A fast virtual optimization of clamping conditions,
    tacking is possible
    A coupling of Simufact.welding and
    Simufact.premap allows a prediction of the
    phase composition during and after welding
    A coupling of Simufact.welding and
    Simufact.forming allows process-chain modeling
    Large industrial structures can be analyzed and
    optimized

    Thank you very much for your attention!


    attention!
    simufact engineering gmbh
    Tempowerkring 3
    21079 Hamburg
    Tel.: 040-790 162-0
    Fax: 040-790 162-22
    [email protected]
    www.simufact.de

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