best welded

Welding structure simulation

Simufact.welding 3.1

What is Simufact.welding?
Virtual process design
Temperature distribution in components and heat
transfer into clampings
Prediction of welding distortions and
residual stress during welding and after
releasing tools
Simulation of local material properties
(e.g. flow stresses or phase fractions) Simufact.welding is directed to welding
Graphical presentation and export
of tracking points
Simulation of process chain and
further mechanical analysis

Simufact.welding
Slide 2

specialists in research, development and

manufacturing.
There is no need to be a specialist for
computer aided calculation methods.

What can Simufact.welding offer?

Virtual process design of welding processes including tacking, fixing concept and
pre-heating

Simufact.welding
Slide 3

What can Simufact.welding offer?

Virtual process design of welding processes including tacking, fixing concept and
pre-heating

Simufact.welding
Slide 4

What can Simufact.welding offer?

Temperature distribution in components and heat transfer into clamping tools

Simufact.welding
Slide 5

What can Simufact.welding offer?

Prediction of distortions during and after clamping and prediction of residual
stresses due to welding

Simufact.welding
Slide 6

What can Simufact.welding offer?

Fast process variations by copy function
For instance minimization of distortions via varying the clamping conditions

Simufact.welding
Slide 7

What can Simufact.welding offer?

Automatical real simulation of possible gap formation during welding by high
resolution contact between components

Gap ?
F?
F?

F?
F?

Simufact.welding
Slide 8

What can Simufact.welding offer?

Simulation of local material properties e.g. changed flow stresses of phase
fractions

Simufact.welding
Slide 9

What can Simufact.welding offer?

Graphical presentation and export of tracking points

Simufact.welding
Slide 10

How does Simufact.welding works?

Geometry and meshing
Weld paths and fillermaterial
Mechanical and thermal boundary
conditions
Heat source modeling
Time management
Prediction of local material properties
Postprocessing

Simufact.welding
Slide 11

Geometry and meshing

Finite element meshes can be imported from a Nastran-bulk-file (*.bdf)

Automatic mesh refinement during welding for high thermal gradients

Simufact.welding
Slide 12

Weldpath and fillermaterial

Easy definition of weld paths via node picking or by import of a csv-file

with path coordinates
Automatic generation of a FE-mesh for filler material

Simufact.welding
Slide 13

Mechanical boundary conditions

Automatic generation of clamping geometries

Adjustable clamping times
Contact between components
and filler materials

Contact between components and tools:

Spring stiffness C:
Automatic determination of the direction
rectangular to the contact surface

Initial force F:
Automatic determination of the
direction rectangular to the contact
surface

Simufact.welding
Slide 14

Therma boundary conditions

Automatic detection of free surfaces for heat dissipation

Heat flux definition on contact surfaces
Variable initial temperature for preheated work pieces
Predefined default values

Initial work-piece
temperature

Convection:

Qc = -h A (T1 - T2)
Heat transfer via surface contact and
heat transfer coeffient

QCHT = A (T1 - T2)

Emissions coeffizient :
Stefan-Boltzmann-equation:

QE = - A (T14 - T24)
(0 1)

Simufact.welding
Slide 15

Heat source models

Positioning and rotation of heat sources

Automatic projection on surface with offset function

Simufact.welding
Slide 16

Heat source models

Combination of heat sources using offset function

Simufact.welding
Slide 17

Time management

Simufact.welding
Slide 18

Material modeling during welding

Simufact.welding includes simufact.premap modules (Nancy model)
Interface to JMatPro etc.

Austenite
austenite
whrend
during
Schweien
welding

Martensit
martensite
nach
after cooling
Abkhlen

Simufact.welding
Slide 19

Postprocessing

Simufact.welding
Slide 20

Three-point bending tests

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

Highest level of
accumulated
plastic strains at
the weld seam
close to forming
tools
Simufact.welding
Slide 21

Deep drawing and welding

Residual stress after welding
Without forming results

With forming results

Lifting distortion of the cover on

the opposite edge

Calculated without forming results

Accumulated plastic strains after welding

Calculated with forming results

After welding the component is highly plastically deformed and under high residual
stresses which influence the stress distribution and distortions during and after welding
Simufact.welding
Slide 22

Welding and deep drawing

Implementation of welding distortions into forming analysis
Temperature distribution during welding

Acc. plastic strains during welding

Simufact.welding
Slide 23

Model: Forming of tailored blanks

accumulated plastic strains after forming

Deep drawing and welding

Implementation of plastic strains and residual stresses for into welding analysis

Forming simulation including unclamping, cooling, trimming and positioning for welding can be
performed in simufact.forming
Import of formed geometry from arc-files
Import of forming results from arc-files via introducing a pre state block in the dat-file (in
simufact.welding 3.1.0 by hand)

Right mouse click Import geometries

Simufact.welding
Slide 24

Calculation quality

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
standart DIN SPEC 32534-1: Numerical welding simulation Execution and documentation)

2-Layer TIG weld

material

316LNSPH / 316L

voltage

9V

current

155 A

welding velocity

40,2 mm/min

Simufact.welding
Slide 25

distortion angle
measurement: 0.033
simulation: 0.032

Conclusion

Welding simulation can be user-friendly. Simufact.welding

offers:
a.) an automatic mesh refinement
b.) handles incompatible meshes
c.) offers a fillet generator for FE-Meshes
d.) a fast method to define weld paths and
process orientation
e.) heat source models and interfaces to
process simulations
f.) modeling of clamping tools
A fast virtual optimization of clamping conditions, tacking is
possible
A coupling of simufact.welding and simufact.premap allows a
prediction of the phase proportions during and after welding
A coupling of simufact.welding and simufact.forming allows
process-chain modeling

Simufact.welding
Slide 26

simufact engineering gmbh

Tempowerkring 3
21079 Hamburg
Tel.: 040-790 162-0
Fax: 040-790 162-22
office@simufact.de
www.simufact.de