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    LS PREPOST CWM Pre Processor

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    LS PREPOST CWM Pre Processor

    Uploaded by

    532110007
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    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    10 views19 pages

    LS PREPOST CWM Pre Processor

    Uploaded by

    532110007

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 19

    Weld simulation in LS-DYNA and LS-PREPOST

    Mikael Schill
    Anders Jernberg
    LS-DYNA One code strategy
    “Combine the multi-physics capabilities into one scalable code for solving
    highly nonlinear transient problems to enable the solution of coupled multi-
    physics and multi-stage problems”

    Explicit/Implicit

    Heat Transfer Incompressible Fluids R7

    Mesh Free CESE Compressible Fluid R7


    EFG,SPH,Airbag Particle Solver

    User Interface Electromagnetism R7


    Elements, Materials, Loads

    Acoustics Frequency
    Response, Modal Methods

    Discrete Element Method


    Welding capabilities - Solver
    ■ State of the art parallelization
    ■ Thermal and Mechanical solvers are run in a staggered approach

    Mechanical Solver Thermal Solver

    Based on the actual temperature the based on the actual geometry the
    mechanical solver calculates: thermal solver calculates:

     Forces and corrseponding stress  Heat from weld source


     Temperature dependent constitutive  Heat conductance
    material properties  Cooling from convection
     Thermal expansion  Update of the actual temperature.
     Update of the actual geometry
    LS-DYNA welding capabilities – Weld Source
    ■ The weld source is modeled using a Goldak double ellipsoid heat
    source.
    ■ The type of weld is chosen by using different geometry of the heat
    source.
    ■ It is defined by geometrical
    measures a_r, a_f, b and c
    ■ Also, the power distribution
    can be adjusted from rear to
    front.

    Direction

    Source

    2015-11-16 4
    LS-DYNA welding capabilities – Material
    ■ The element can either be solid, ”Liquid” or ”Ghost”.
    ■ When the material is ”Ghost” it has the following properties:
    ■ Low Stiffness
    ■ No thermal expansion
    ■ Specific heat related to the heating of the material from the weld arc
    ■ No thermal conductivity
    ■ When the temperature reaches a specified temperature, material is activated
    and recieves ”material” properties.
    Weld arc

    Ghost

    Activated material

    Temperature

    2015-11-16 6
    LS-DYNA welding capabilities – Material
    ■ Apart from the ghost element function, the material model also includes
    Anneal functionality.
    ■ Above a specified temperature, all history variables such as hardening and
    back stress are set to zero.
    ■ However, the stresses are calculated from equilibrium equations.
    ■ The material model includes piecewise hardening whith seamless
    isotropic/kinematic portions.
    ■ All properties are temperature dependent

    2015-11-16 7
    MAT_244

    ■ *MAT_UHS now has the possibility to have element


    activation by temperature similar to *MAT_CWM
    ■ Supports annealing where history variables are cancelled
    out.
    ■ Can be combined with *MAT_CWM_THERMAL
    ■ By default, the phase start temperatures are the same for
    both heating and cooling.
    ■ When using advanced kinetics input (REACT=1), the start
    temperatures can be input as load curves.
    ■ Temperature dependendent thermal expansion for austenite
    and hard phases
    ■ Added load curve for transformation induced strains.

    Recent developments for thermo-mechanically coupled simulations in LS-DYNA with


    Focus on welding processes, Thomas Klöppel, Tobias Loose, 10th European LS-DYNA
    Conference 2015, Würzburg, Germany, 2015
    LS-DYNA welding capabilities – Material

    Von Mises stress


    Temperature Effective plastic
    strain

    2015-11-16 9
    Pre-processing issues
    ■ Set weld path of source and direction node
    ■ Set the weld speed, type and power
    ■ Assign the clamping
    ■ Assign the thermal Boundary conditions
    ■ Assign material data (ghost, liquid or solid)
    ■ Determine the process order
    ■ Quickly becomes complicated for multistage analysis – Pre-processor is
    needed

    PASS 1 COOL 1 PASS 2

    Temperatures, deformation and history variables are transferred through the process
    Pre-processor goals
    ■ Set up weld path and weld direction
    4
    ■ Easy to change welding order
    • Fillet 2
    Weld1 • Cooling time 60 s
    ■ Automatic transfer of results from
    one stage to the next • Power 3500 W
    3 speed 2 mm/s
    1 • Weld
    Weld 2

    ■ Automatic switch of material from • Clamping set 4


    Ghost, Liquid and Solid Weld 3 • Cooling time 200s

    ■ Easy setup of clamping and thermal 2


    BC for each process step

    ■ Connection to optimization software


    Input to Weld simulation setup
    ■ Geometry of structure and welds
    ■ Weld and orientation paths as beam
    elements.
    ■ The mesh can be generated by other
    pre-processor such as ANSA or ANSYS
    workbench and imported to LS-PREPOST
    ■ The welds can be either merged to
    the structure or connected by
    thermal “tied”contacts.
    ■ Material of structure and welds
    ■ Sets of nodes that define
    mechanical boundary constraints
    ■ Segments that define the different
    thermal boundaries.
    Control files and output
    ■ LS-PREPOST includes recommended Welding and Cooling ”control files”.
    ■ The file can be edited by the user or if a control file is placed in the working
    directory, LS-PREPOST will use that file instead of the default.

    ■ Each welding pass and cooling is written into its own directory.

    2.1 Process step 2, weld pass

    2.2 Process step 2, cooling


    Pre-processing – Welding plan
    ■ By clicking the boxes, the
    welding order is determined.
    ■ Possibility to add or remove
    stages.
    ■ Double clicking on the rows
    opens the corresponding
    definitions.
    ■ To each weld, corresponding
    clamping and thermal boundary
    condition can be chosen.
    ■ If the properties are defined,
    the box is coloured green.
    ■ When the process is set up, an
    LS-DYNA input file is exported.
    ■ The setup of the welding
    simulation can be saved/loaded
    from an ASCII file.
    Pre-processing – Weld properties
    ■ Each weld has its own property
    regarding:
    ■ Pool geometry (GOLDAK)
    ■ Velocity
    ■ Power
    ■ Efficiency
    ■ Cooldown time
    ■ The user can specify the
    number of timesteps/element
    ■ Weld path and orientation is
    identified by clicking
    ■ Possibility to unify an input to
    several welds.
    ■ Solution timestep is determined
    by timesteps per element.
    Pre-processing – Weld path
    ■ Path and orientation is determined by
    “beam” elements.
    ■ Selected by clicking
    ■ Weld can be animated by slider
    ■ Weld pool geometry is visible in the
    geometry window
    Pre-processing – Boundary conditions
    ■ Mechanical constraints are applied on sets of
    nodes.
    ■ Visible in graphics window at selection
    ■ Air cooling is automatically identified
    ■ Other cooling boundaries (such as clampings) are
    identified by sets of segments
    Pre-processing – Weld optimization
    ■ The welding simulation setup is output to
    an ASCII file.

    ■ The ASCII file can be used together with


    LS-OPT to optimize weld order, heat
    input, cooling times etc.
    Summary
    ■ LS-DYNA has a one-code strategy together with long term commitment of
    running large models with high level of parallelization.

    ■ This makes the LS-DYNA software a strong contender for incremental welding
    simulations.

    ■ To solve the pre-processing issues, DynamoreNordic has started the process of


    developing a module for welding simulations in LS-PREPOST

    ■ The pre-processor will solve the main issues of setting up production type
    welding simulations.

    ■ We are open for suggestions from users for further development.

    ■ BETA version in early fall 2015.


    Thank you!

    Your LS-DYNA distributor and


    more

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