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The Welding SimulationSolution
Courtesy WAGON Automotive GmbH
ESI GROUP
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February 2006
Copyright ES I GROUP
The Welding Simulation
Solution
SUMMARY OF THE WELDING OFFER
ESI GROUP
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The Welding S imulation Solution i ES I GROUP© 2006 ESI Group (released: April-06)
CONTENTS
CONTENTSGetting Value 4
Industries Objectives ---------------------------------------------------------------------- 4 Industries Benefits ------------------------------------------------------------------------- 4 Improvement of the Performance and Quality of the Product ----------------- 6 Distortion Engineering – Cost Reduction -------------------------------------------- 7 Position in the Product Cycle ----------------------------------------------------------- 9 Beneficiaries ------------------------------------------------------------------------------ 10 The Team Behind „The Welding S imulation Solution‟ -------------------------- 11
Representative References 12 Industry ------------------------------------------------------------------------------------- 12 University and Institutes --------------------------------------------------------------- 12 General ES I GROUP ------------------------------------------------------------------- 12
Applications 13 Transient Welding ----------------------------------------------------------------------- 13 Steady S tate Welding------------------------------------------------------------------- 28 Macro Bead Welding -------------------------------------------------------------------- 29 Welding Assembly ----------------------------------------------------------------------- 31 Friction Welding -------------------------------------------------------------------------- 40 Friction S tir Welding --------------------------------------------------------------------- 41 Spot Welding ------------------------------------------------------------------------------ 41
Scientific Work 48 What do the Experts Say -------------------------------------------------------------- 48 Applications ------------------------------------------------------------------------------- 51
Available Software Tools 70 Meshing – VISUAL MESH ------------------------------------------------------------ 70
Shell Meshing ---------------------------------------------------------------------------- 70 Shell-Solid-Meshing -------------------------------------------------------------------- 70 Solid-Meshing ---------------------------------------------------------------------------- 71 Automatic Shell Meshing -------------------------------------------------------------- 71 Automatic Link of Shell Components with Solid Welding J oints -------------- 72 How to Generate Quickly Meshes for Transient and Macro StepWelding Simulation -------------------------------------------------------------------- 72
Transient and Steady State Welding ----------------------------------------------- 75 Welding Wizard -------------------------------------------------------------------------- 75 Local Model Wizard --------------------------------------------------------------------- 76 Heat Source Fitting Tool --------------------------------------------------------------- 77 Hardness S imulation Wizard --------------------------------------------------------- 78 Metallurgical Parameters Fitting Tool ----------------------------------------------- 79 Multi-Pass Welding --------------------------------------------------------------------- 80 Spot Welding ----------------------------------------------------------------------------- 81 Friction Stir Welding -------------------------------------------------------------------- 84 Welding Material Databases ---------------------------------------------------------- 85 Check Box -------------------------------------------------------------------------------- 86
Macro STEP Welding ------------------------------------------------------------------- 90 The Macro Bead Advisor -------------------------------------------------------------- 90
Welding Assembly ----------------------------------------------------------------------- 91
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ESI GROUP ii The Welding S imulation Solution(released: April-06) © 2006 ESI Group
CONTENTS
The Assembly Advisor ----------------------------------------------------------------- 91 P AM-A SSEMBLY Database Manager ------------------------------------------------- 92 P AM-A SSEMBLY --------------------------------------------------------------------------- 92
Available Engineering Tools 93 Toolbox CD-ROM ------------------------------------------------------------------------ 94 Engineering Guide ----------------------------------------------------------------------- 94 Examples CD-ROM --------------------------------------------------------------------- 94
Documentation 95 Welding User‟s Guide ------------------------------------------------------------------ 95 Knowledge Included -------------------------------------------------------------------- 96
Key Technology 97 S imulated Physics ----------------------------------------------------------------------- 97 Movement of Heat Sources along Weldlines ------------------------------------- 97
Removal of Material History ---------------------------------------------------------- 98 Material P roperties Depending on P hases or Material S tatus --------------- 99 Volume Changes During Phase Transformations ---------------------------- 100 Phase Transformations of Hardenable S teel ----------------------------------- 102 Almgmn – Kinetics of Recrystallization ------------------------------------------ 103 Almgsi – Kinetics of Precipitates --------------------------------------------------- 104 Dedicated Mechanical Material Laws -------------------------------------------- 104 Mesh Independent Application of Properties ----------------------------------- 106 Chewing Gum Method for Filler Material ---------------------------------------- 106 Classic FEM Tools -------------------------------------------------------------------- 107 Fully Automatic Solver---------------------------------------------------------------- 107 Numerical S tability --------------------------------------------------------------------- 107
Linear System of Equations Solvers ---------------------------------------------- 108 Hardware P latforms ------------------------------------------------------------------- 108 Summary – Technical Features and Key Technology ----------------------- 109 Illustration – Technical Features and Key Technology ---------------------- 110
Chaining with Stamping and Crash Simulation 115 Chaining S tamping and Welding -------------------------------------------------- 115 Chaining Welding and S tamping -------------------------------------------------- 116 Chaining Welding and Crash ------------------------------------------------------- 116
Chaining with Fatigue and Structural Analysis 117 Basic Concept and Interface -------------------------------------------------------- 117
Welding-Assembly of Large Structures 118 Overview --------------------------------------------------------------------------------- 118 Basic Concept -------------------------------------------------------------------------- 119 Positioning in the Product and Process Workflow ---------------------------- 121 SYSWE LD and P AM-A SSEMBLY - S imulation Solution for WeldingAssembly ------------------------------------------------------------------------------- 122
A typical Workflow --------------------------------------------------------------------- 124
ESI Group Profile 130 Pioneering Virtual Engineering ----------------------------------------------------- 130
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The Welding S imulation Solution iii ES I GROUP© 2006 ESI Group (released: April-06)
CONTENTS
ESI Group Consulting Services 134 Committing to Customers ----------------------------------------------------------- 134 Service offer - Welding --------------------------------------------------------------- 134
Training Courses 135 ES I Group Learning Solutions ------------------------------------------------------ 136 Worldwide Learning Centers ------------------------------------------------------- 137 Meshing Welding Applications ----------------------------------------------------- 138 Welding S imulation - Getting it Right --------------------------------------------- 139 Understanding the Material Background ---------------------------------------- 140 Understanding Numerical Parameters and Nonlinear Geometry --------- 141 How to Perform and Document Projects Effectively -------------------------- 142 Welding Assembly S imulation ------------------------------------------------------ 143 Welding Assembly Simulation of Large Heavy Industry Structures ------ 144 Stamping and Welding S imulation Coupling ----------------------------------- 145
Understanding the Theoretical Background of Welding S imulation ------ 146
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ES I GROUP 4 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP4
GETTING VALUE
INDUSTRIES OBJECTIVES
The Industries objectives are
Market effectively
Reduce costs
Shorten time to market
Reduce downtimeImprove productivity
Increase efficiency
Improve profitability
Gain access to new, global markets
Enhance product quality and reliability
Introduce innovation
Reduce weight
Reduce scrap and rework
Avoid failure
The Welding Simulation Solution has been designed to get value with respect to thelisted objectives, though computer modeling.
INDUSTRIES BENEFITS
Using ‘The Welding Simulation Solution’, you will be able to
Minimize production cost
Minimize structural weight
Minimize distortions (distortion engineering)
Minimize product risk in the earliest stage of the product development cycle
Master assembly problems
Ascertain the level & distribution of residual stresses
Control and minimize hardness and grain size in the FZ and HAZ
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SYSWELD®2006 5 ES I GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 5
Avoid cold cracks
‘The Welding Simulation Solution’ helps you to
Improve the product design
Identify better processes or materials
Meet procedure approvals
Meet product acceptance standards
Implement new production methodologies
Meet contract quality requirements
Your objective to provide the best product possible is achieved bysimulation-based process design through
Improved understanding of the effects that lead to distortions and residual stresses
Subsequent optimisation of the product design and the manufacturing processes
A keyfeature of ‘The Welding Simulation Solution’ is the sensitivityanalysis
Major influence: A change in the parameter of 10% leads to a change of 100% inresults
Moderate influence: A change in the parameter of 10% leads to a change of 10% inresults
Low influence: A change in the parameter of 10% leads to a change of 1% in results
The sensitivity parameters studied are
Welding process itself
Welding process parameters
Process stability (gap)
Welding sequenceNumber and length of welding joints
Position of welding joints
Clamping conditions
Design
Material properties
Material combinations
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ES I GROUP 6 SYS WELD®2006(released: April-06) © 2006 ESI Group
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Transformation behaviour of the material
IMPROVEMENT OF THE PERFORMANCE ANDQUALITY OF THE PRODUCT
Controlling material characteristics via the computer can significantly enhance theperformance and quality of a product. Controlling residual stress via the computer cansignificantly enhance the quality and structure‟s service life.
Residual stress control via modeling can:
Reduce weight
Maximize fatigue performance
Lead to quality enhancements
Minimize costly service problems
„The Welding Simulation Solution‟ was specifically developed for this purpose. Itoffers all existing Finite Element based methodologies to control material characteristicand residual stress via the computer.
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SYSWELD®2006 7 ES I GROUP© 2006 ESI Group (released: April-06)
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DISTORTION ENGINEERING – COST REDUCTIONDesigning the welding fabrication via the computer to minimize or control distortioncan significantly reduce fabrication costs.
Fabrication design via modeling can:
Eliminate the need for expensive distortion corrections
Reduce machining requirements
Minimize capital equipment cost
Improve quality
Permit pre-machining concepts to be used
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ES I GROUP 8 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP8
„The Welding Simulation Solution‟ was specifically developed for this purpose. Itoffers all existing Finite Element based methodologies to control welding fabrication
via the computer.
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SYSWELD®2006 9 ES I GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 9
POSITION IN THE PRODUCT CYCLE
‘The Welding Simulation Solution’ is placed at the earliest stage of the product cycleto
Study distortion influencing parameters in
o Material
o Process
o Design
Take preventive measures for low-distortion welding constructions
Avoid over-dimensioning
‘The Welding Simulation Solution’ is placed at the earliest stage of the product cycleto choose the best
Welding process
Type of welding joint
Number and length of welding joints
Sequence and welding direction
Clamping conditions
‘The Welding Simulation Solution’ is pl aced at the earliest stage of the product cycleto
Choose the best design dimensions regarding cost and weight
Make the design decisions taken more safer
Minimise post-design costs by avoiding failure or repair at a late stage of theproduct cycle
Understand the physics which lead to distortions, residual stresses and failure duringin-service behaviour
Derive or improve design rules from sensitivity analysis
Understand the differences between adjustment-specimen and real parts
Improve established production processes
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ES I GROUP 10 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP10
BENEFICIARIES
The beneficiaries are
Producers of Welded mass production parts
o High volume of Welding joints /day
o Anybody using Welding robots
Producers of mission critical parts (space mission equipment, power plants)
Producers of expensive parts (turbines, power plants)
In Terms of Industrysectors
Vehicle and Aerospace Industry
Heavy Industry
Nuclear Industry
Chemical Industry
Suppliers
Universities and Research Institutes
These include:
Product manufacturing
Product design
Durability evaluation
Crash worthiness
Structural behavior - protection of functionality
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SYSWELD®2006 11 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 11
THE TEAM BEHIND ‘THE WELDINGSIMULATION SOLUTION’
By choosing „The Welding Simulation Solution‟, you will benefit from the experienceof a team dedicated to welding and heat treatment simulation solutions. You will haveaccess to more the 60 years of simulation engineering expertise.
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ES I GROUP 12 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP12
REPRESENTATIVE REFERENCES
INDUSTRY
Air Liquide, ALCOA, AW Engineering, Bechtel Bettis, BIAS, BOSCH, CEA Saclay.CEA Valduc, Centro Sviluppo Materiali, CETIM, CNRC-NRC, Corus Technology BV,DaimlerChrysler AG, DENKI KOGYO, ELECTRIC BOAT, FHG IWM, FHG IWS,FRAMATOME, GKN, HITACHI, KENKI HYUNDAI, INA, India Ghandi Center for
Atomic Research, JFE SYSTEMS, KAIST, KATECH, Knolls Atomic PowerLaboratory, NISSAN, POSCO, Pratt & Whitney Aircraft, PSA, RENAULT, RollsRoyce, SAMSUNG, SERCO, SETVAL, SHANGHAI BOASTEEL, SOLLAC,
SUZUKI, TOSHIBA, TOYOTA, UAM, VW, VZLU, ZF
UNIVERSITY AND INSTITUTES
Many Universities and Institutes around the World are using the Welding SimulationSolution of ESI for scientific purposes
GENERAL ESI GROUP
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SYSWELD®2006 13 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 13
APPLICATIONS
TRANSIENT WELDING
“Using the finite element code SY SWELD at Fraunhofer Institute for Mechanics ofMaterials complex thermo-mechanical analyses of the resulting distortion and residualstresses due to the welding of aluminum structures have been performed. With the aidof heat sources which were especially developed for the weld bead of aluminum andadapted to the temperature field and macro-sections from experimental measurementsan excellent agreement of calculated and measured distortion of an automotiveconstruction was reached”
Dr. Dieter Siegele, Head of Department Safety and Availability of Components,Marcus Brand, Welding Mechanics, Fraunhofer Institute for Mechanics ofMaterials, IWM, Woehlerstr. 11, 79108 Freiburg, Germany.
Courtesy AUDI AG, FHG IWM
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ES I GROUP 14 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP14
Courtesy AUDI AG, FHG IWM
Courtesy VW AG
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SYSWELD®2006 15 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 15
BMW 1-series, cross tube of front axle carrier, Courtesy BMW
BMW 1-series, cross tube of front axle carrier, Courtesy BMW – Temperature field validation
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ES I GROUP 16 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP16
Courtesy BMW
Joining of a „Schweller‟ Chaining with stamping simulation – Courtesy AUDI AG
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SYSWELD®2006 17 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 17
Welding of a rear axle wing – Courtesy BMW AG
Transient Welding of a door component – Courtesy WAGON Automotive GmbH
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ES I GROUP 18 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP18
Transient MIG Welding of a B-Pillar-Roof connection – Courtesy AUDI AG
Transient Welding of an engine carrier – Courtesy VW /FHG IWM /WAGGON
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SYSWELD®2006 19 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 19
Study of weld positioning variations – Courtesy UAM
Single pass welding of an aluminum rim modeled with solid models
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ES I GROUP 20 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP20
Single pass welding of a steel rim modeled with shell elements
Chaining of forming and welding simulation – ESI example
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ES I GROUP 22 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP22
Method of resolution – Courtesy IWB
Laser beam welding task – Courtesy IWB
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SYSWELD®2006 23 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 23
Final distortion – Courtesy IWB
Measurements– solid model, shell mode without chaining, shell mode with chaining – Courtesy IWB
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ES I GROUP 24 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP24
Rolls Royce validations - Courtesy Rolls Royce
Multi-pass Repair Welding in Nuclear Industry – Courtesy UAM (former Vitkovice)
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SYSWELD®2006 25 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 25
Multi-pass Welding – Courtesy AREVA NP (Former FRAMATOME)
Multi-pass Welding – Courtesy AREVA NP (Former FRAMATOME)
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ES I GROUP 26 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP26
Multi-pass Welding – Courtesy SERCO
Validation of transient welding simulation for Heavy Industry – Courtesy UAM
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SYSWELD®2006 27 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 27
Validation of Welding of Aluminum profiles – Courtesy FORD /Jaguar
Validation of Welding of Aluminum profiles – Courtesy FORD /Jaguar
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ES I GROUP 28 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP28
STEADY STATE WELDING
Courtesy Aerospatiale
Steady state welding – ESI example
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SYSWELD®2006 29 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 29
MACRO BEAD WELDING
Energy release in an exhaust system joint – Courtesy Renault
Macro bead welding and chaining with stamping simulation – ESI training example
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ES I GROUP 30 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP30
Typical Heavy Industry Specimen – ESI training example
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SYSWELD®2006 31 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 31
WELDING ASSEMBLY“ A very good agreement has been achieved between measurements and simulations”
Marek Slovacek, Ph.D, Head of the department Technology processes, Instituteof the applied mechanics Brno, Ltd., Veveri 95, 611 00 Brno, Czech republic,about the Local-Global Approach
Validation of the local-global method for Heavy Industry – Courtesy UAM
The local-global method in Heavy Industry – Courtesy UAM and ANSALDO
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ES I GROUP 32 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP32
Welding of a front axle carrier– Courtesy BMW AG
Welding Assembly of a chassis component – Courtesy Renault
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SYSWELD®2006 33 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 33
Laser Welding – Courtesy Benteler
Welding simulation of an axle component – Courtesy DaimlerChrysler
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ES I GROUP 34 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP34
Welding simulation of an axle component – Courtesy DaimlerChrysler
Welding simulation of an axle component – Courtesy DaimlerChrysler
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SYSWELD®2006 35 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 35
Welding Assembly of a bumper– Courtesy GM
Welding Assembly and comparison with measurements – Courtesy Alcoa
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ES I GROUP 36 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP36
Welding Assembly of stiffeners in ship building – Publication SHI HANPAM 2003
Welding Assembly in Heavy Industry
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SYSWELD®2006 37 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 37
Welding of a large T-joint in Heavy Industry – ESI example
Welding of a large T-joint in Heavy Industry – ESI example
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ES I GROUP 38 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP38
Welding of a large T-joint in Heavy Industry – ESI example
Welding of a large T-joint in Heavy Industry – ESI example
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SYSWELD®2006 39 ESI GROUP© 2006 ESI Group (released: April-06)
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Welding of thick material in Heavy Industry – ESI example
Welding of thick material in Heavy Industry – ESI example
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ES I GROUP 40 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP40
Chaining of Stamping and Welding S imulation – ES I example
FRICTION WELDING
Friction Welding – Courtesy DaimlerChrysler AG
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SYSWELD®2006 41 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 41
FRICTION STIR WELDING
Friction Stir Welding – ESI Example
SPOT WELDING
The Local –Global Method applied in spot welding applications – ESI example
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ES I GROUP 42 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP42
Spot welding – Courtesy CORUS
Spot welding simulation and validation
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SYSWELD®2006 43 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 43
Spot welding simulation and validation
Spot welding simulation and validation
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ES I GROUP 44 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP44
Spot welding simulation and validation
Spot welding simulation and validation
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SYSWELD®2006 45 ESI GROUP© 2006 ESI Group (released: April-06)
Copyright ES I GROUP 45
Spot welding simulation and validation
Spot welding simulation and validation
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ES I GROUP 46 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP46
Spot welding simulation and validation
Spot welding simulation and validation
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SYSWELD®2006 47 ESI GROUP© 2006 ESI Group (released: April-06)
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Spot welding – Courtesy WMG
Chaining of welding and crash simulation
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ES I GROUP 48 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP48
SCIENTIFIC WORK
WHAT DO THE EXPERTS SAY
“Using the finite element code SY SWELD at Fraunhofer Institute for Mechanics ofMaterials complex thermo-mechanical analyses of the resulting distortion and residualstresses due to the welding of aluminum structures have been performed. With the aidof heat sources which were especially developed for the weld bead of aluminum andadapted to the temperature field and macro-sections from experimental measurementsan excellent agreement of calculated and measured distortion of an automotiveconstruction was reached”
Dr. Dieter Siegele, Head of Department Safety and Availability of Components,Marcus Brand, Welding Mechanics, Fraunhofer Institute for Mechanics ofMaterials, IWM, Woehlerstr. 11, 79108 Freiburg, Germany.
“ A very good agreement has been achieved between measurements and simulations”
Marek Slovacek, Ph.D, Head of the department Technology processes, Instituteof the applied mechanics Brno, Ltd., Veveri 95, 611 00 Brno, Czech republic,about the Local-Global Approach
"SYSWELD has not only accompanied our scientific research, concerning the
fundamental principals of welding distortion and residual stresses of structures, but alsoopened the way for considering complex 3-d components. Using either transientcomputation methods or reduced models helped to achieve excellent results concerningthe structural behaviour of welded parts."
Dipl.-Ing. Loucas Papadakis, Fügetechnologien, Institut für Werkzeugmaschinen, und Betriebswissenschaften (iwb), TU München,Boltzmannstr. 15, 85748 Garching
"At the Institute for Machine Tools and Industrial Management iwb (TechnischeUniversität München), SYSWELD is intensively used for more then 5 years. It isapplied as a strong tool for detecting part specific properties, e.g. stresses and distortion,
during and immediately after treating by welding in an early state of Product LifeCycle. We look upon this program favorable in the production of tomorrow due to thestill unexploited possibilities of this program."
Dipl.-Ing. Sven Roeren, Fügetechnologien, Institut für Werkzeugmaschinen, undBetriebswissenschaften (iwb), TU München, Boltzmannstr. 15, 85748 Garching
“The Bremer Institut für angewandte Strahltechnik (BIAS) uses SYSWELD for thesimulation of various welding processes and the calculation of welding distortions. Oneessential advantage of SY SWELD is the consideration of phase transformations whichare important for residual stress calculation in laser heat treatment. SYSWELD has beenapproved itself as a very useful tool to estimate process parameters ahead ofexperiments whereby time and costs could be reduced.”
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Dipl.-Ing. Jörg Woitschig, BIAS, Bremer Institut für angewandte Strahltechnik, Abt. Werkstoffe und Modellierung
“In the very complex field of welding and heat treatments simulation, newmethodologies are necessary in order to follow the severe industry demand of reliabilityand low time cost. Sysweld is a numerical code that with its own routines andimplemented metallurgical laws taken from International literature, fully satisfy theserequirements. A great work we have done to verify the reliability of welding simulation
with Sysweld by comparing numerical and experimental results in terms of temperaturehistory and residual stresses; very good agreements were found. Another key factor isthe excellent technical and numerical support we have always found by the ESI-Groupmembers.”
P. Ferro, F. Bonollo, A. Tiziani, DTG - University of Padova, Stradella S.Nicola 3 36100 Vicenza (Italy)
“The Finite-Element-Program Sysweld has a logically founded and well elaboratedstructure of program and organization of data. The language of input-files is easilyunderstandable. The possibility of calculating of phase transformation, the possibility ofdefining moving heat sources by weld lines in a simple way, the possibility of definingarbitrary functions in the data input, the possibility of using different solutionprocedures, and many other helpful features making Sysweld an excellent tool forresearch, which is not only used for welding simulation.”
Dipl.-Ing. Tobias Loose, European Welding Engineer, Lehrstuhl fürStahlbau, Universität Karlsruhe (TH), Kaiserstraße 12, D-76131 Karlsruhe
“In our Institute of Manufacturing and Welding Technology we use the Finite-Element-Code SYSWELD for the modeling of welding residual stresses both in public and inindustrial R&D projects. The SYSWELD Code has a good functionality and a highscientific level. The ESI working group is ever striving to inform the users how to do agood welding modeling, and it distributes regularly useful information among the users.The ESI presentations are an excellent tool in our Institute's lectures on WeldingSimulation.”
Dr.rer.nat. U.Semmler, Chemnitz University of Technology, Institute ofManufacturing and Welding Technology Reichenhainer Str. 70, D-09126
Chemnitz
“The welding simulation is a large domain that covers from trivial to complexproblems, where various phenomena take part and require interpretation. This fact is
valid in the both fields – research and industry. In that context a proper simulation codeshould supply possibilities for free definition of physical and phenomenological models;possibilities for their coupling into complex analyses; abilities for creating routines as
well as a suitable tool for presentation of the results. Definitively, SYSWELDsuccessfully attain these requirements.”
N. Doynov, Dr.-Ing., Chair of Joining Technology, Technical University ofBrandenburg, Cottbus, Germany
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ES I GROUP 50 SYS WELD®2006(released: April-06) © 2006 ESI Group
Copyright ES I GROUP50
“The commercial FE-software Sysweld provides the means to model and analyzecomplexly transformations of structure for metallic materials, and steel in particular.Therefore, it is now possible to investigate welding and heat treatment in a realisticmanner. We are not aware of any other commercial software, which provides thefunctionality to realize such investigations with the required complexity. Sysweld is aflexible software which allows for scientific investigations to facilitate research, as wellas practical applications, such as the optimization of welding processes or the predictionof complex residual stress behaviors states of residual stresses) in a variety of metallicmaterials. Sysweld was used in innovative research on welding processes with silicaglass and has also shown excellent results. The application and partial improvement ofthe software forms a vital basis for our ability to do research and for the acceptance ofour findings.”
Prof. Dr.-Ing. habil. Frank Werner, Head of Department Steel Structures,Bauhaus-Universität Weimar, Marienstrasse 5, 99423 Weimar, Germany
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APPLICATIONS
"At the Institute for Machine Tools and Industrial Management iwb (TechnischeUniversität München), SYSWELD is intensively used for more then 5 years. It isapplied as a strong tool for detecting part specific properties, e.g. stresses and distortion,during and immediately after treating by welding in an early state of Product LifeCycle. We look upon this program favorable in the production of tomorrow due to thestill unexploited possibilities of this program."
Dipl.-Ing. Sven Roeren, Fügetechnologien, Institut für Werkzeugmaschinen, undBetriebswissenschaften (iwb), TU München, Boltzmannstr. 15, 85748 Garching
Scientific work at IWB – Courtesy IWB
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SLV Munich
Comparison with measurements – Aluminum welding – Courtesy SLV Munich
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Laser Welding – INZAT
Laser Welding - INZAT
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Scientific work at IWB – Courtesy IWB
Laser Cladding – Courtesy FHG IWS
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Electron Beam Welding – Courtesy see slide
Electron Beam Welding – Courtesy see slide
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TIG-Dressing – Courtesy University of Weimar
Laser beam welding of silica – Courtesy University of Weimar
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Welding of Nickel based Superalloys – Courtesy University of Padova
Welding of Nickel based Superalloys – Courtesy University of Padova
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Welding of Nickel based Superalloys – Courtesy University of Padova
Welding of Nickel based Superalloys – Courtesy University of Padova
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Welding of Nickel based Superalloys – Courtesy University of Padova
Welding of Nickel based Superalloys – Courtesy University of Padova
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Welding and surface technology – Courtesy BIAS
Welding and surface technology – Courtesy BIAS
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Scientific work at BTU Cottbus
An external process model for weld pool simulation of the laser beam welding has beendeveloped. This model considers all relevant physical phenomena that influence the
shape of the weld pool, e.g. convection and Marangoni effect. The process modelcalculates furthermore the temperature field in a local domain inside and around the weld pool (Micro-model). The temperatures are transferred to the global FE-model(Macro-model) by chimera approach. A procedure in SY SWELD has been created forthis purpose.
This procedure allows correction of the temperature field at every time step consideringthe temporary conditions, obtained from the mechanical response of the body, e.g. thegap opening during welding. It also involves simple parameters for adjusting the weldpool size and shape to experimental data.
Benefits:
o Improved precision of the calculated displacements due to precise description of thetemperature field
o Simulation of laser beam welding, regarding the heat input variation after the gapopening
Laser Welding – Micro-Macro Model taking into account changes in the gap and fluidflow – Courtesy BTU Cottbus
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Laser Welding – Micro-Macro Model – Courtesy BTU Cottbus
Laser Welding – Micro-Macro Model – Courtesy BTU Cottbus
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Heat source optimization – Courtesy University of Padova
Heat source optimization – Courtesy University of Padova
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Phase proportions in Multi-Pass Welding – Courtesy University of Padova
Multi-pass welding – Courtesy Institute de Soudure
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Welding simulation using advanced meshing techniques– Courtesy CNRS
Welding simulation using advanced meshing techniques– Courtesy CNRS
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Welding applications – Courtesy TU Olomouc
Welding applications – Courtesy TU Olomouc
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Viscoplastic modeling – courtesy see slide
Viscoplastic modeling – courtesy see slide
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Welding of plastics – Courtesy Bayerisches Laserzentrum
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AVAILABLE SOFTWARE TOOLS
MESHING – VISUAL MESH
Shell Meshing
ESI training example
Shell-Solid-Meshing
Courtesy “Automobilarbeitskreis”
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Solid-Meshing
Courtesy AUDI AG
Automatic Shell Meshing
Automatic (Batch) meshing of WELDING ASSEMBLY components, based on userdefined rules – ESI example
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Automatic Link of Shell Components with Solid WeldingJoints
For the purpose of Welding Assembly, global components meshed only with shellelements are linked with so-called Welding Macro Elements, which are a brand newdevelopment. Shell meshing is not time consuming and the components are linkedautomatically via Welding Macro Elements. The inner forces resulting from a transientor steady state welding simulation of a local model are then transferred to the WeldingMacro Elements and the assembly simulation is performed.
Automatic insertion of welding joints in shell meshed components - CourtesyRENAULT
How to Generate Quickly Meshes for Transient and MacroStep Welding Simulation
P AM-A SSEMBLY performs distortion simulation with a global mesh that consists of Welding Macro Elements and shell meshes of components. Temporarily, solid elementshave been created to insert the Welding Macro Elements. Welding trajectories have
been used to generate the temporary solid meshes by extrusion or block.
With V ISUAL MESH, it is easily possible to generate from the generated meshes a shellonly or shell-solid mesh for Classic Transient or Macro Step simulations. Only littleorganizational work is needed to generate the required meshes.
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Generated shell-mesh in P AM-A SSEMBLY
With some further selective load of generated meshes, it is also easily possible togenerate a shell-solid mesh.
Generated shell-solid mesh, meshes from a P AM-A SSEMBLY session merged in V ISUAL MESH
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Generated shell-solid mesh, meshes from a P AM-A SSEMBLY session merged in V ISUAL MESH
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TRANSIENT AND STEADY STATE WELDING
Welding Wizard
The Welding Wizard is an easy-to-use Graphical User Interface to facilitate the efficientset-up of welding simulations. No knowledge in Finite Element methods is needed toset up and run steady state and transient welding simulations. It combines a mesh,material data information from a material database, heat source information from a heatsource database and individual process parameters in a way that input decks are createdthat can be automatically interpreted by the S YSWELD solver. The input decks consist ofthe definition of material properties, constraints and loads, and the command sequencefor the solver.
The Welding Wizard dialogue box
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Local Model Wizard
The Local Model Wizard is a tool to set up automatically - based on practical process
parameters only - rotational and translational T-, Butt-, and Overlap joints as well as welding joints based on a custom defined cross-section. The Local Model Wizard can be used either to quickly perform welding simulations of basic welding specimen forarbitrary purposes or as a tool to fill a local model database for P AM-A SSEMBLY . Noknowledge in nonlinear Finite Element methods is required to use this tool.
The Local Model Wizard
The Local Model Wizard – Predefined local models
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Heat Source Fitting Tool
The calibration of the heat transfer into the structure is one of the most important tasks
in a welding (assembly) simulation. To check the process feasibility is however not thetask of the engineer in this context – welding assembly simulation means computationof the heat effects of welding rather then process feasibility simulation. Consequently – for the purpose of the computation of the heat effects of welding - welding joints can beassumed that can be manufactured under valid process conditions, as for exampledescribed in American, Japanese or European norms. The task of the heat source fittingtool is to find - based on a heat transfer model - process parameters in a way that valid
joints are produced. A fine tuning can be done based on micrographs and temperatureand hardness measurements. Four joint profiles are predefined to fit the heat source: T,Butt, Overlap and User Defined. An automatic post-processing provides you with themost important results. The calibrated heat source can be stored in a database and usedlater for arbitrary purposes.
The Heat Source Fitting tool
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Hardness Simulation Wizard
For any project set up with the Welding or Heat Treatment Wizard it is now possible to
compute the hardness out of an easy to use dialogue box. The chemical composition istaken directly from the material database or can be entered by hand if not yet present.The hardness computation has been enhanced to high carbon contents above 0.5%.
The Hardness Simulation Wizard
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Metallurgical Parameters Fitting Tool
It helps to fit the metallurgical parameters of phase transformations during welding.
CCT diagrams as well as phase transformations during heating are calibrated with thistool.
CCT diagram fitting and automatic plotting
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Multi-Pass Welding
Multi Pass Welding Joints are a very important part of steel constructions and pressure
vessel components. Defects occur very often in them. Residual tensile stresses havenegative influence on the structure lifetime and the brittle fracture resistance. Residualstresses create a balanced system of inner forces, which exists even under no externalloading. The welding joints have to designed and produced with care.
ESI group has developed a multi-pass Wizard that helps the user to manage multi-pass welding. It simplifies significantly the workload of the user. All welds involved in themulti-pass process are computed according to the same scheme initially defined in the
Welding Wizard. When the project is saved the mesh is checked, updated and all inputdata for all welding simulation are created.
Tools for Multi-pass Welding
By using the check dialog box, after the selection of the welding project, the list of welding joint is proposed. The mesh that will be used for the computation of the
selected joint is updated such as the standard ‘Check’ procedure can be used.
Tools for Multi-pass Welding After the selection of the welding project, the Solve editor box is opened. The „solve asa single weld‟ option allows to run the computation of the selected joint independentlyof all previous one. This option must be used for a checking purpose. The list of the
joints to be computed must be selected before validation. For the whole simulation, all welds must be selected.
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Workflow of the Spot Welding Wizard
Workflow of the Spot Welding Wizard
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Friction Stir Welding
Friction stir welding (FSW) is an emerging welding process, which was developed
initially for aluminum alloys by TWI. This process involves strong interactions betweenthermal, metallurgical, and mechanical phenomena as shown in the following figure.
Mechanics
Tem eratures
Heat transfer
Metallurgy
Latent heatsMicrostuctural
modifications Microstucturalmodifications
Thermaldissipation
Temperatures
Coupling between heat transfer, metallurgy and mechanics
In the FSW process, the heating is provided by the mechanical dissipation due to thestrains and the contact conditions between the tool and the material.
In SY SWELD, a three-dimensional model based on the Finite Element Method has been developed accounting for the thermal and the mechanical phenomena in a fullycoupled approach. The stress equilibrium, the energy and the mass conservation are
solved in an Eulerian frame for the stationary step of the process, considering anincompressible non-Newtonian fluid. The mechanical stresses are calculated from the
velocity field and the thermal dissipation can be easily deduced.
Temperature profile (°C) for a shear stress and streamlines for a shear stress
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Welding Material Databases
The welding solution from ESI comes with a database that incorporates the most
commonly used materials in the Industry.The material data can be managed in Microsoft Excel . A Macro exists which exportsmaterial data in the S YSWELD database format.
Phase transformation and melting enthalpy
Material data management in Microsoft Excel
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Check Box
The check box is a tool to check simulation projects that have been set up with the
Welding Wizard. All necessary checks are available through one dialogue box.
Check of the Weld-line
Check of the heat exchange with the surroundings
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Check of the heat transfer to the surroundings as a function of the temperature
Check of the power input
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Check of the applied power density
Check of material groups
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Check of the clamping conditions
Check of material properties
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MACRO STEP WELDING
The Macro Bead Advisor
This is an easy-to-use Graphical User Interface to facilitate the efficient set-up of Welding simulations with the Macro Bead Deposit Method. It allows you to simulatethe heat transfer into the structure in macro time steps, which vastly reduces thecomputation time for transient welding simulations. Y ou can now simulate parts likesuspension systems - or ship block components in a transient manner, within areasonable time range.
Release of energy in macro time steps
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WELDING ASSEMBLY
The Assembly Advisor
This is an easy-to-use Graphical User Interface to facilitate the efficient set-up of Welding Assembly simulations. The Welding Assembly Advisor opens a hugesimulation application field – distortion control of large maritime and automotivestructures with a reasonable amount of computer memory and computation of results
within a extremely short time range.
The Welding Assembly Advisor was the first tool that enabled to use the local-globalmethod for the simulation of Welding Assembly. Starting from 2006, P AM-A SSEMBLY is available for the set up of Welding Assembly simulations. The Welding Assembly
Advisor in S YSWELD will remain; It allows the definition of very complex simulations,
which require sometimes an advanced knowledge in the method of Finite Elements.
The Welding Assembly Advisor
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P AM-A SSEMBLY is a new integrated solution for the simulation of Welding Assembly.The main purpose of this tool is to compute the displacements after each step of anassembly sequence and unclamping. Using P AM-A SSEMBLY , the user is able tooptimize, compare and finally select the best possible welding sequence and choice ofclamping tools.
In P AM-A SSEMBLY , the Local-Global method is applied to simulate the effects of Welding Assembly. It is the most efficient method for large assembly designs.
P AM-A SSEMBLY graphical user interface
AVAILABLE ENGINEERING TOOLS
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TOOLBOX CD-ROM
It contains Tutorials, User‟s Guides, and the Engineering Guide. It enables engineers tounderstand and solve welding simulation problems.
ENGINEERING GUIDE
It covers all the background knowledge needed to work straight forward on heattreatment and welding problems
Contents of engineering guide
EXAMPLES CD-ROM
It covers the major applications in Heat Treatment and Welding (Release in April 2006)
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DOCUMENTATION
WELDING USER’S GUIDE
The Welding User‟s guide covers the usage of the Welding Wizard as well as all theengineering knowledge related to steady state and transient welding.
Welding User‟s Guide
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KNOWLEDGE INCLUDED
Usage of the Welding Wizard
Messages Managed by the Welding Wizard
How to Choose Numerical Parameter Files
Frequently asked questions
Way to Work
The Most Important Tips and Tricks
Guidelines for Large Problems
Guidelines for Transient Welding of Shells
Advanced Welding Modeling
Access to Electronic Manuals – Getting Info from Manuals
Quick Checklist
A Tutorial – Keys to Convergence
Step by Step Example
Systematical Example
How to Present Results in an Effective Format
Typical Postprocessing Results
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REMOVAL OF MATERIAL HISTORY
S YSWELD is the only commercial Finite Element code in the market that masters theremoval of the material history in case a defined temperature is exceeded. This featureis mandatory to reach the required high precision in transient welding simulations, incombination with unmatched computation speed and convergence behavior.
Phase transformations and removal of the material history
The welding heat source is moving along the weld path. Due to thermal gradients,plastic strains are built up in front and beside the heat source. In case the temperatureexceeds a certain value, the material history is fully automatically removed. This is thereality.
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MATERIAL PROPERTIES DEPENDING ONPHASES OR MATERIAL STATUS
All material properties can depend on temperature and phases.
Thermal conductivity depending on phases
Yield stress depending on phases
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VOLUME CHANGES DURING PHASETRANSFORMATIONS
Volume changes during phase transformations and all related mechanical phenomenalike for example transformation plasticity are taken into account.
Dilatometer test
Dilatometer test
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Change of volume during martensite transformation
Kinetic of phase transformations
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PHASE TRANSFORMATIONS OF HARDENABLESTEEL
Isothermal and continuous phase transformations of hardenable steel are taken intoaccount.
CCT diagram of hardenable steel
Simulated phase transformations
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CCT and TTT diagram
ALMGMN – KINETICS OF RECRYSTALLIZATION
The hardening due to mechanical treatment and the loss of hardening due to the heateffects of welding is treated in welding simulations.
Loss of strength due to recovery effects
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ALMGSI – KINETICS OF PRECIPITATES
The precipitation hardening and the loss of hardening due to the heat effects of weldingis treated in welding simulations.
Loss of strength due to dissolution of precipitations
DEDICATED MECHANICAL MATERIAL LAWS
All mechanical phenomena that occur in a welding process are accurately simulated.
Implemented mechanical models
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MESH INDEPENDENT APPLICATION OFPROPERTIES
In fact, metallurgical laws are the basis of a drastically reduction of the time needed toset up a welding model. All material properties are applied independent of the mesh,depending only on the evolution of temperature and phase transformations or changes inthe material status.
Mesh independent application of material properties
CHEWING GUM METHOD FOR FILLERMATERIAL
The modeling of filler material requires no specific user interaction beside the definitionof the filler zone in the mesh. The addition of the material is managed through a specificmetallurgical law, which transfers material having properties close to chewing gum tomolten material, above a user defined temperature. More complex FEM techniques like
birth and death are not needed.
Automatic management of the filler material along the moving heat source
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CLASSIC FEM TOOLS
All kind of classic Finite Element tools like external loads, clamping conditions, etc. areavailable.
Classic clamping conditions
FULLY AUTOMATIC SOLVER All the key technology as presented in this chapter is included in a transient weldingsimulation. Nevertheless, the solution process requires not any user interaction and isfully automatic. Not any knowledge in numerical mathematics is needed to set up andrun a welding simulation.
Solve box
NUMERICAL STABILITY
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The numerical stability of S YSWELD is unmatched. Despite the fact that all the complexphysics is simulated, the maximum possible time step can be applied without numericalproblems. Consequently, you can run S YSWELD always with the maximum possiblesimulation speed.
Automatic management of the filler material along the moving heat source
LINEAR SYSTEM OF EQUATIONS SOLVERS
Direct optimized sparse and a highly optimized iterative solver are available for thesolution of the linear system of equations.
HARDWARE PLATFORMS
S YSWELD is running on recent Windows, Linux and Unix computers.
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SUMMARY – TECHNICAL FEATURES AND KEYTECHNOLOGY
Movement of welding heat sources along arbitrary path in space
Automatic and mesh independent calibration of the heat transferred into thestructure along the weld path
Phase transformation and melting enthalpy
Phase and material status dependent material properties
Fully automatic treatment of removal and birth of material history
Fully automatic and mesh independent application of material properties dependingon temperature and phases
Fully automatic treatment of yet to be deposited material
Nonlinear mixture rules for phase properties
Restoring of strain hardening during transformation
Dedicated integration of plasticity laws
Nonlinear geometry (large strains and large displacements/rotations)
Consistent tangent material matrix for isotropic, kinematic and mixed hardening,
including phase transformations An iterative linear system of equation solver allows the treatment of very largestructures on PC‟ s
Generalized plane to plane contact
Linear and parabolic solid elements, linear solid elements with incompatible modes,linear and parabolic shell elements
Shell-solid models
Welding dedicated numerical tools
Welding simulation tools for all kinds of Industry and all kinds of metallic material
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ILLUSTRATION – TECHNICAL FEATURES ANDKEY TECHNOLOGY
Temperature field
Filler material modeling
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Simultaneous systematical comparison of the removal of the mechanical history and thetemperature field in JASC Animation Shop©
Simulation of phase transformations
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Residual stresses – hardenable steel
Residual stresses – non hardenable steel
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Cumulated plastic strains
Final yield stress distribution
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Residual stresses after tempering
Change of process conditions and wall thickness
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MES HES FOR TRANSIENT AND MACRO STEP S IMULATION
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CHAINING WITH STAMPING AND
CRASH SIMULATION
CHAINING STAMPING AND WELDING
The basic goal of distortion engineering
Chaining of stamping and welding simulation
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MES HES FOR TRANSIENT AND MACRO STEP S IMULATION
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CHAINING WELDING AND STAMPING
Chaining of welding and stamping simulation – Courtesy AUDI AG
CHAINING WELDING AND CRASH
Chaining of welding and crash simulation
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CHAINING WITH FATIGUE AND
STRUCTURAL ANALYSIS
BASIC CONCEPT AND INTERFACE
An interface exists to transfer results from the Simulation World of Metallurgy to theSimulation World without Metallurgy
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WELDING-ASSEMBLY OF LARGE
STRUCTURESOVERVIEW
P AM-A SSEMBLY is a new integrated solution for the simulation of Welding Assembly oflarge structures. The main purpose of this tool is to compute the displacements aftereach step of an assembly sequence and unclamping. Using P AM-A SSEMBLY , the user isable to optimize, compare and finally select the best possible welding sequence andchoice of clamping tools.
In P AM-A SSEMBLY , the Local-Global method is applied to simulate the effects of Welding Assembly. It is the most efficient method for large assembly designs.
General view of the Pam-Assembly Graphical User Interface
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BASIC CONCEPT
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P AM-A SSEMBLY serves as an easy-to-use front end to perform Welding Assemblysimulations for large structures. The physics of welding is not ignored – it is fullytreated in the local models, which are simulated with the S YSWELD software. The basicidea behind the Local-Global method implemented in P AM-A SSEMBLY is to provideprecision in Advanced Manufacturing simulation – without simplification of the physicsof welding on the one hand, but very easy to use and very efficient with respect tocomputation time - even for large assemblies – on the other hand.
In P AM-A SSEMBLY , global components meshed only with shell elements are linked withso-called Welding Macro Elements, which are a brand new development. Shell meshingis not time consuming and the components are linked automatically via Welding MacroElements. The results of a transient or steady state welding simulation on a local modelare then transferred to the Welding Macro Elements and the assembly simulation isperformed.
For the user, the manipulation of P AM-A SSEMBLY is simple: Only the meshedcomponents, weld-lines that represent the position and direction of welding seams, and
the computed results of a local model (accessible through a database) must be provided. After having defined clamping conditions and a welding sequence, a linear elasticanalysis is performed to compute the distortion due to the Welding Assembly process.
Consequently, the user of P AM-A SSEMBLY need not be familiar with non-linear FiniteElement simulations. All the complex physics is only used to generate the local model.This concept allows designers and manufacturing practitioners to quickly simulatedistortion due to the heat effects of welding, without getting involved in non-linearFinite Element issues or numerical methods.
The local models are created in S YSWELD as required, with an automatic local modelgenerator, or they can be selected from a local model database, which can be generatedoff-line. As a consulting service, ESI can provide extended local model databases,
which are appropriate to individual company needs.Thermal cycles, phase transformations, changes in material status, stresses, plasticstrains, thermal strains, yield stress of the newly formed material and all other resultsrelated to a transient welding simulation are available for the local model.
This method to simulate welding assembly has been validated for more than five years with many Industrial partners.
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POSITIONING IN THE PRODUCT AND PROCESS
WORKFLOW
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SYSWELD AND PAM-ASSEMBLY - SIMULATIONSOLUTION FOR WELDING ASSEMBLY
For very large structures, such as maritime and automotive structures, standard step-by-step welding methodologies are not feasible since these methods require significantcomputation time and computer memory size.
In order to overcome this limitation without detriment to result quality, ESI Group hasdevised an innovative solution based on the Local-Global methodology and on the
Welding Macro Element (WME) technology. The Local-Global methodology has beenavailable in S YSWELD for four years via the Assembly Advisor tool. The WMEtechnology has been implemented in a new product called P AM-A SSEMBLY . This newgeneration product is a logical extension of the Finite Element Code S YSWELD.
Historical EvolutionThis new technology offers new perspectives as the global computation is achieved onshell elements only, instead of a combination of shell and solid elements, or solidelements only. Since only 2D elements are manipulated in order to create the globalmesh, the computation time is strongly reduced due to the reduction of the number ofdegrees of freedom.
P AM-A SSEMBLY is developed in a new user environment common to P AM-STAMP 2G. All related user-friendly tools are therefore available: the graphic features, the pre-processor and the post processor.
P AM-A SSEMBLY is above all an editor that allows the user to define, prepare and set-upan assembly simulation based on the Local-Global methodology and on the WME
technology. It automatically generates all the input data required by S YSWELD toexecute the simulation. P AM-A SSEMBLY uses the S YSWELD solver to manage thecalculations on the Welding Macro Elements, as well as the global computation of thestructural distortions. It is important to note that the user does not need to be familiar
with S YSWELD in order to perform a P AM-A SSEMBLY simulation.
P AM-A SSEMBLY also contains an automatic meshing tool to create the mesh of the seam weld and to prepare the finite element model required for the solver.
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Organization of Pam-Assembly
This new software with its innovative WME technology is specially dedicated todecreasing costly design errors. P AM-A SSEMBLY allows user-defined weld sequencingand facilitates the optimization of part geometry, material parameters and processparameters during the early stages of a new design cycle, avoiding expensiveengineering changes that could occur later.
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A TYPICAL WORKFLOW
The following illustrates the basic workflow of a Welding Assembly simulation. Asystematic and complete example is provided with P AM-A SSEMBLY .
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ESI GROUP PROFILE
PIONEERING VIRTUAL ENGINEERING
ESI Group is a pioneer and world-leading provider of digital simulation software for productprototyping and manufacturing processes that take into account the physics of materials.
Founded in 1973 by four Berkeley Ph.D. graduates, E SI Group now occupies a unique position inthe high-potential Product Lifecycle Management (PLM) market.
ESI Group has developed an entire suite of coherent, industry-oriented solutions torealistically simulate a product‟s behaviour during testing, to fine tune the manufacturing processes insynergy with the desired product performance, and to evaluate the impact of the environment onproduct usage.
Drastically reducing costs and development lead times, ESI Group has integrated into itsglobal "Virtual Try-Out Space" (VTOS ) offer major competitive advantages by progressively eliminatingthe need for physical prototypes during the product development phase.
With the collaboration of nearly 500 high-level specialists worldwide, the company andits global network of agents provide direct sales and technical support to customers in more than 30countries.
The development of ESI Group is based on continuous innovation; this has earned theGroup the qualification “innovative company” by the French National Research Agency, Anvar.
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ESI GROUP CONSULTING
SERVICESCOMMITTING TO CUSTOMERS
Since more then 30 years, the interest of our clients is the center of our work, whether weare providing software, support or services. Over several decades, our clients haveexperienced us as experts in our field. We are at any time at your disposal to improveproduct performance and productivity on the one hand and shortening development timesand cost on the other hand.
Consulting services are performed by highly skilled engineers, who, thanks to their in-depthengineering knowledge and their process understanding, are ready to team with you to help
you to adopt an integrated innovation approach.
SERVICE OFFER - WELDING
ES I Group offers support of cus tomers and services in all engineering fields involvingthe following tasks
Development of innovative new welded designs and welding processes
Improvement of the performance and quality of welded products
Cost reduction of all welding fabrication processes
Distortion engineering
These tasks can involve the following welding processes and materials
Single pass welding, all kind of processes and materials
Multi-pass welding, all kind of processes and materials
Spot welding, all kind of materials
Friction welding, all kind of materials
Friction stir welding, all kind of metallic materials
You will find a good selection of our service portfolio in the chapters „Applications‟ and„Scientific Applications‟ of this document.
Do not hesitate to contact a subsidiary of ES I Group in your area. You will find the contactdata either on the back cover of this document or at www.esi-group.com.
We look forward to working with you soon!
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TRAINING COURSES
ESI Group Learning Solutions
2006
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ESI GROUP LEARNING SOLUTIONS
Reliable, Flexible and Efficient Learning Programs
ESI Group has over 30 years of expertise in software application training courses.
These classes are taught by highly skilled engineers responsible for consulting and supportactivities, who, thanks to their years of practice and field experience, are fully prepared toanswer to the participants‟ needs.
For optimal knowledge transfer, E S I Group honours the following criteria, underlining theeffectiveness of its learning programs:
- class sizes are kept small to ensure adequate attention for all attendees,- time is set aside to work on each participant‟s particular demands, - training manuals and a computer are provided for each attendee,- demonstrations and practical exercises are carried out throughout the training,- ...
Participants come away from these classes with a good understanding of all the features ofthe ES I software of their choice as well as targeted knowledge for immediate application.The courses also provide an excellent forum for ES I Group customers to work with eachother and share their experience in digital simulation.
From introductory to advanced or specialized sessions, E S I Group offers an expansiveeducational program.
In addition to standard courses, ES I Group can set up a dedicated learning program tailoredto your needs and knowledge of the software, with flexible training times, content andduration. Customized courses take place either at one of ES I Group‟s worldwide learningfacilities or on-site, at your facility.
With decades of training experience and a proven educational methodology, ES I Groupsoftware learning courses are the best way to learn about the features and capabilities of thesoftware products you work with daily.
We look forward to working with you soon!
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WORLDWIDE LEARNING CENTERS
A broad and expert training network
With field subsidiaries and regional technical support offices spanning four continents, E S IGroup provides personalized training services and high-level support to its customers world-wide.
Seoul (South
Korea)
Tokyo (Japan)
+Santa Clara (CA,
USA) for ESICFD Inc.
ESIGroup Paris(France)
Lyon (France)
Aix (France)
Lausanne,Switzerland
Plzen (Czech
Republic)
Seoul (South
Korea)
Tokyo (Japan)
+Santa Clara (CA,
USA) for ESICFD Inc.
ESIGroup Paris(France)
Lyon (France)
Aix (France)
Lausanne,Switzerland
Seoul (South
Korea)
Tokyo (Japan)
+Santa Clara (CA,
USA) for ESICFD Inc.
ESIGroup Paris(France)
Lyon (France)
Aix (France)
Lausanne,Switzerland
Seoul (South
Korea)
Tokyo (Japan)
+Santa Clara (CA,
USA) for ESICFD Inc.
ESIGroup Paris(France)
Lyon (France)
Aix (France)
Lausanne,Switzerland
ESIGroup Paris(France)
Lyon (France)
Aix (France)
Lausanne,Switzerland
Plzen (Czech
Republic)
Plzen (Czech
Republic)
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