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

office@simufact.de

www.simufact.de