simufact welding - simulating manufacturing
DESCRIPTION
Simufact Welding - Simulating ManufacturingTRANSCRIPT
Welding Simulations with
Simufact.welding
SimDay 2013 Szimulációs 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?
simufact.welding is designed for welding engineers in research, development and production who do not have to be experts in numerical simulation!
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
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
F ?
Gap ?
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 forming
Acc. plastic strains during welding
Implementation of welding distortions into forming analysis
model: forming of tailored blankstemperature distribution during welding
accumulated plastic strains after formingaccumulated plastic strains during forming
residual stresses after welding
Without forming results With forming results
Simulated without forming results
Lifting of the cover on the opposideedge
Accumulated plastic strains after welding
Simulated with forming results
Accumulated plastic strains after welding
Geometry and Meshing
Weld paths andFillermaterial
Clamping- and Boundary conditions
Heat source modeling
Time mangementTime 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
Spring stiffness C:
Automatic determination of the direction
rectangular to the contact surface
Contact between base and fillermaterial
Contact between components and tools:
Clamping devices can be generated automatically
Clamping duration is considered
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 welddistortion angle
measurement: 0.033°
simulation: 0.032°
material 316LNSPH / 316L
voltage 9 V
current 155 A
welding velocity 40,2 mm/min
measurement
simulation
(Simufact.welding 3.10)
Two alternative strategies:W2 W1
W3
?
W4W5
W6
W1
W9
A
W2
W8
W3
?
C3
W4
W5
W6W7
W9W10
BProcess :- MAG WeldingFiller Wire Diameter : - 0.8 mm (Copper Coated MS Wire)
Filler material provides contact between
parts and is automatically added during
the simulation of the welding process:
WeldingHefting
After cooling to room temperature
+1.24 mm+2.13 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 weldingphase 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
ThankThank youyou veryvery muchmuch forfor youryour attentionattention!!
simufact engineering gmbh
Tempowerkring 3
21079 Hamburg
Tel.: 040-790 162-0Tel.: 040-790 162-0
Fax: 040-790 162-22
www.simufact.de