MANUFACTURING

VIRTUAL

SYSWELD
for HEAT TREATMENT
Martensite
distribution

Retained
austenite

Final
distortions

Residual stresses

Courtesy: ZF

Influence of heat treatment on

various gear shapes

SYSWELD, the Driving Force

Induction heating of
driveline components

ANSWERING ENGINEERS QUESTIONS

SYSWELD efficiently provides answers to the basic questions from heat
treaters and designers:

Is the selected heat treatment process feasible ?

Is the selected steel appropriate ?
Is the selected quenching media suitable ?
Is the process window safe against process tolerances ?
Is the part hard where it should be hard ?
Is there any crack risk occurring during the process ?
Are the obtained distortions acceptable ?
Are the residual compressive stresses high enough and well positioned ?

Courtesy:
GKN Automotive GmbH

Residual stresses in a
c a m s h a f t a f t e r q u e n ch i n g

FINITE ELEMENT MESH

Automatic layered meshing of two dimensional cross-sections for fast

engineering evaluations
Automatic tetrahedral meshing for most complex shapes requiring minimun

SYSWELD enables
heat treaters to
treatment proces
computer, rather
shop floor trial-a
method. Resultin
than 20 years of
SYSWELD is the l
the simulation of
processes.
SYSWELD is instr
reduction, impro
quality and deliv
performance.

SYSWELD uses ad
element methods
complex materia
SYSWELD can sim
such as:

investigation of CAD geometry

Automatic hexahedral meshing for large parts
Structured three dimensional meshing to provide high accuracy

surface harden
induction
laser
electron beam

through harden
direct
austempering
martempering

thermo-chemic
treatment
carburizing
nitriding
carbonitriding

tempering

2 D l ay e r e d m e s h p e r f e c t l y d e s i g n e d
for the physics of heat transfer

COMPREHENSIVE MATERIAL AND

QUENCHING MEDIA DATABASE
SYSWELD provides a comprehensive database, for the main part classes such
as rings, shafts, gears and engine components.
Bainite
distribution

The database includes various types of steel such as:

Case hardening steels

Hardening and tempering steels
Ball and roller bearing steels
Steels for surface hardening

And quenching media such as:

High performance quenching oils

Dual-range fast quenching oils
Marquenching oils
Vacuum quenching oils
Synthetic oils for quenching and tempering
Polymer quenchants

Mesh

C a r b o n e n r i ch m e n t
Martensite distribution

Case hardening of a gear

SYSWELD allows
grain size, tempe
phases, distortio
stresses, plastic
mechanical prop

... for Heat Treatment Simulation Technology

MULTIPHYSICS
POST-PROCESSOR
The multiphysics post-processing capabilities
provide instanteneous process information for
the evolution of:
Heating and cooling rates

Bainite distribution

Distortions

Hardness
Metallurgical structure of the material
Distortions
Yield stress of the modified material
Plastic strains

Te m p e r a t u r e f i e l d t w o s e c o n d s
a f t e r q u e n ch i n g s t a r t s

Martensite distribution

H e a t Tr e a t m e n t o f a 8 0 0 m m t r a i n w h e e l Computation steps
T R E A T M E N T

Stresses

HEAT TREATMENT ADVISOR

WORKING THE ENGINEERING WAY
The heat treatment advisor technology enables the
simultaneous modeling of complex physical phenomena such as
heat transfer, phase transformations and mechanics.

FINITE ELEMENT SOLVER

cal heat

analysis of
erature field,
ons, residual
strains and
erties.

Hardness

Residual Stresses

Temperature field

ing

ning

Te m p e r a t u r e f i e l d

Courtesy: SKF

H E A T

dvanced finite
s to model
l behavior.
mulate processes

SYSWELD provides a fully automatic Jominy

end-quench hardenability test. When the
measured data is reproduced by the simulation,
the user is able to predict perfectly the core
hardness of arbitrary part shapes. A precise
simulation of the Jominy test is the key to
accurate analyses of real-world situations.

The solution of the finite element problem includes all nonlinear physics of heat treatment. The solver is built on a robust
architecture and provides an automatic solution for heat
treatment problems, covering all related complex mathematics
and material physics.

F O R

rumental in cost
ovement of
very

JOMINY TEST

S Y S W E L D

s designers and
analyse heat
sses on the
r than using
and-error
ng from more
f development,
leading tool for
f heat treatment

U s e r- S p e c i f i c Pa ck a g e s
Two packages are available:
Heat treatment for engineering models for heat treatment shops, research centers and the education market.
It offers a reasonable model size limitation - without any technical limitation - at an appealing price.
Heat treatment full package provides unlimited model size to simulate large and complex parts.

How to become familiar with heat treatment simulation engineering

Introductory, intermediate and advanced training courses are offered by each local office on a regular basis.

SYSWELD - THE COMPLETE HEAT TREATMENT

SIMULATION ENGINEERING SOLUTION
The solution includes:
An engineering guide covering all aspects of heat

treatment simulation
A comprehensive primer, which guides the user, step by step,

through an extended industrial example

A wide range of pre-computed examples, covering most

industrial tasks

Distortion of a ring after

n o n - s y m m e t r i c q u e n ch i n g

Projection of physical quantities between meshes - accurately

fitting to the physics of heat treatment

C a r b o n e n r i ch m e n t

ESI GROUP AND HP: A PARTNERSHIP

FOR CHALLENGING TIMES
ESI Group and HP work together to meet the
increasingly demanding requirements of realworld design situations, with ever increasing
model sizes. This close partnership helps you to
stay competitive - now and for years to come.
For more information on the ESI Group - HP
partnership
and
HP
products,
visit
www.hp.com/go/hptc or contact your local HP
representative.

About ESI Group

F-SYSHT-01 - Copyright ESI Group 2003

Editor of virtual testing solutions, ESI Group is a pioneer and world leading provider of digital simulation for
prototyping and manufacturing processes that take into account the physics of materials. ESI Group has
developed an entire suite of coherent, industry oriented applications to realistically simulate the product's
behavior during testing, to fine tune the manufacturing processes in synergy with the desired product
performance, and to evaluate the environment's impact on product usage. ESI Group's portfolio, which has
been industrially validated and combined in multi-trade value chains, represents a unique collaborative,
virtual engineering solution, known as the Virtual Try-Out Space (VTOS), enabling a continuous improvement
on the virtual prototype. By drastically reducing costs and development times, VTOS solutions offer major
competitive advantages by progressively eliminating the need for physical prototypes.

w w w. e s i - g ro u p . c o m

ESI GROUP HEADQUARTERS

ESI Group
6, rue Hamelin
BP 2008-16
75761 Paris Cedex 16 - France
Phone: +33 (0)1 53 65 14 14
Fax: +33 (0)1 53 65 14 12

ESI GROUP MARKETING

ESI Software
99, rue des Solets
SILIC 112
94513 Rungis Cedex - France
Phone: +33 (0)1 41 73 58 00
Fax: +33 (0)1 46 87 72 02

PAM-SYSTEM and all PAM-product names are trademarks of ESI Software - All other trademarks are the property of their respective owners - Specifications are subject to change without notice.