Welding Simulation Suite 2012

Insert the front cover image in this header, then position and resize it !
WELDING SIMULATION SUITE 2012

Release Notes
WELDING SIMULATION SUITE 2012

SYSWELD 2012 Visual-WELD 7.5 WELD PLANNER 2012
RELEASE NOTES
The documents and related know-how herein provided by ESI Group subject to contractual conditions are to remain confidential. The CLIENT shall not disclose the documentation and/or related know-how in whole or in part to any third party without the prior written permission of ESI Group.
2012 ESI Group. All rights reserved.
Janvier 2012
GL/SYWE/11/11/00/A
WELDING SIMULATION SUITE 2012 2012 ESI Group
RELEASE NOTES (released: Jan-12)
CONTENTS
WELDING SIMULATION SUITE ......................................... 1 SYSWELD SOLVER ........................................................... 3
SYSWELD Improve Fatigue Performance.................................................. 3 SYSWELD Solving Large Models .............................................................. 6
Dang Van Criteria for Low Amplitude High Cycle Fatigue Life Analysis ...... 3 SYSWELD DMP Performance Optimization / Macro Transient Reduction File Size Assignment .................................................................................. 6 SYSWELD DMP Performance Optimization / A New Label OPTIMIZE for the Fusion .................................................................................................. 6 SYSWELD DMP Performance Optimization / Positive Definite MATRIX..... 7 SYSWELD DMP Capabilities Enhancement / Usage of Non-Conform Mesh via the REMESH Routine ........................................................................... 7 Spot Weld Advisor Contact Performance Improvement ............................ 16 Automatic Light Post Processing during Computation .............................. 17 Foreword .................................................................................................... 1 Introduction................................................................................................. 2
SYSWELD DMP Capabilities Enhancement DMP / Computation Option with Contact.............................................................................................. 13 End to End Cast-Weld Chaining Simulation / Cast-Weld Interface........... 17
VISUAL-WELD AND VISUAL HEAT TREATMENT ......... 19
Visual-WELD ............................................................................................ 19
General Description .................................................................................. 19 Multiple Database Support ....................................................................... 19 Direct .DAT File Loading........................................................................... 20
Visual-Heat Treatment.............................................................................. 21
General Description .................................................................................. 21 Project Description ................................................................................... 21 Process Definition..................................................................................... 22 Material Properties ................................................................................... 23 Heat Treatment Process (Heating/Carburization/Quenching) ................... 23 Clamping Condition .................................................................................. 25 Loads and Deformations........................................................................... 26 Solution Parameters ................................................................................. 27 General Description .................................................................................. 29 DMP Performance .................................................................................... 30 Export for Cluster...................................................................................... 30
Weld-HT Chaining Solution ...................................................................... 28 Computation Manager .............................................................................. 29
VISUAL-VIEWER 7.6 ........................................................ 31
Location Supports Frame ......................................................................... 31
CONTENTS
ii
WELD PLANNER .............................................................. 33
Management of 3D Model ........................................................................ 33 Spot Weld Simulation ............................................................................... 35

Rigid and Elastic Clamping Condition in Local Frame............................... 38 Release Step Improvement of Very Large Model...................................... 39 Management of Very Large Model Through the Graphic User Interface ... 39
MATERIAL DATA MANAGEMENT .................................. 41
Phase Transformation Calibration Manager (PTCM) ............................... 41 Strain Hardening Calibration Tool ............................................................ 43 Material Data Manager V3.4..................................................................... 44 Interface with WELDWARE ...................................................................... 45
CONTENTS
WELDING SIMULATION SUITE

Foreword
Dear Customer, We are pleased to present the latest Welding Simulation Suite release which includes SYSWELD 2012, WELD PLANNER 2012 and Visual-WELD 7.5. Our major motivation is to implement your requirements for an easy-to-use and robust software package, which includes all the Multi-Physics that is involved in Welding, Heat Treatment and Welding Assembly Simulation. Today, you have at your disposal a single suite of software for all your welding and Heat Treatment assessment and fabrication needs, incorporating the following major elements: Visual-Mesh: A complete meshing tool which supports CAD import, 2D and 3D meshing and editing for linear and quadratic meshes. SYSWELD: A powerful solver which allows addressing all Arc, Electron Beam, Laser Spot welding processes and Carburizing, Carbonitriding, Quenching Heat Treatment processes by taking into account all relevant thermal, metallurgical and mechanical physics which occur during the welds and heat treatment process. Visual-WELD: The new generation fast and easy to use welding simulation tool which covers all the activities of a welding and heat treatment engineer.
Welding Advisor: An easy-to-use Graphical User Interface, to facilitate the efficient setup of Single-Pass and Multi-Pass Welding simulations. HT Advisor: An easy-to-use Graphical User Interface to facilitate the efficient set-up of Heat Treatment simulations. Computation Manager: An easy-to-use computation manager to facilitate the control of full thermal-metallurgical and mechanical welding simulations. Collector Manager: An easy-to-use tool to create, update, delete and modify the different collectors needed for welding simulation. Visual-Viewer for Weld: A new-generation post-processing tool with state-of-the-art plotting utilities. Visual-Viewer is built on a multi-page / multi-plot environment, which enables you to group the data into pages and plots. Complete sessions can be re-run without loss of any data. It is completely command-driven which enables you to execute commands with ease and save time. WELD PLANNER: A dedicated software to support distortion engineering for largescale welded assemblies, making use of a shrinkage method. Engineers use it to identify distortion critical weld joints, clamping conditions and weld sequences to minimize distortion, and the distortion magnitude quickly.
WELDING SIMULATION SUITE SYSWELD Improve Fatigue Performance
Engineering Tools: The Toolbox CD-ROM: It contains Tutorials, Users Guides, and the Engineering Guide. It is available in English language. The Engineering Guide: It covers the background knowledge needed to work straight forward on Heat Treatment and Welding problems. With this solution, the full set of welding engineering methodologies is available: To control material characteristics and residual stress, To keep distortion within tolerances To enhance the performance, the quality of the product and the structures service life.
The following pages will help you navigate through the welding solution. At this point, we would like to thank you for your continued support. Our main goal for the future will be the continuous improvement of the code as driven by your requirements. Kind Regards Yannick Vincent Harald Porzner Frederic Boitout Achutha Herur Yonggang Duan Venugopal A B Product Manager Product Marketing SYSWELD Project Manager Visual-WELD Project Manager SYSWELD Quality Manager Visual-WELD Quality Manager
Introduction
Welding of structures involves complex interactions between thermal, metallurgical and mechanical phenomena leading to residual stress and distortion, which play a major role during subsequent service of these structures. Controlling material characteristics, residual stress and keep distortion within tolerances via the computer can significantly enhance the performance, the quality of the product and the structures service life. Moreover, the numerical design of the welding fabrication will significantly reduce the fabrication costs. The Welding Solution is specially developed for this purpose. It offers the full set of welding engineering methodologies needed by designers, process planners and manufacturing practitioners.
WELDING SIMULATION SUITE SYSWELD Improve Fatigue Performance
SYSWELD SOLVER
SYSWELD IMPROVE FATIGUE PERFORMANCE
Dang Van Criteria for Low Amplitude High Cycle Fatigue Life Analysis
The optimization of structures subjected to Multi-axial High-Cycle Fatigue (MHCF) is a very important subject for many design departments in the Automotive, Aerospace and Energy industries. The fatigue model implemented in SYSWELD and presented hereafter is based on the Dang Van criterion, as presented in [Maitournam M.H., Finite Elements Applications Numerical Tools and Specific Fatigue Problems in High-Cycle Metal Fatigue in the Context of Mechanical Design, K. Dang van and I. Papdoupoulos, Eds., CISM Courses Lectures No. 392, Springer-Verlag 1999, pp. 169-187]. This Dang Van Criterion [DVC] is based on multi meso-macro scales approach which assumes that shakedown occurs before failure initiation. The Dang Van criterion, based on the Lin-Taylor homogenization assumption in order to relate mesoscopic (grain scale) and macroscopic mechanical fields, is defined in terms of linear combination between the hydrostatic pressure: and the mesoscopic resolved shear amplitude: .
According to Dang Van criterion, the fatigue damage appears when the combination of local shear stresses and the hydrostatic stress crosses the borders of a permissible fatigue area:
: hydrostatic part of the stress tensor. : is the mesoscopic shear stress a & b: are the two parameters of Dang Van criterion. tcomp: is the computation time
SYSWELD SOLVER SYSWELD Improve Fatigue Performance
It is common to represent the stress path in a mesoscopic shear versus a mesoscopic hydrostatic stress diagram as schematically shown below.
The line defined by the criterion is the boundary between infinite life and fatigue. Component life for a load path contained completely below the DVC line will be infinite. If any point of the load path is located above the DVC line, fatigue will occur. The parameters and can be expressed by data from two high cycle fatigue tests: ) and reversed torsion (fatigue limit ):
reversed bending (fatigue limit
At the post-processing level, the Dang Van criterion is integrated in SYSWELD in a way to allow users to predict failure initiation. The computation steps are as follows: Reading stress results (Gauss points) Computing maximum value of the criterion over the load path using an appropriate algorithm Storing the Dang Van criterion
The input is the stress tensor as a function of time in a post-processing file of type POST. Only stresses at integration points are used. It is then possible to compute the Dang Van criterion on a set of selected elements and within specific time range. This functionality is available only in continuous media option 2D and 3D.
Dang Van Criteria output Post Processing (Courtesy PSA)
SYSWELD SOLVING LARGE MODELS

SYSWELD DMP Performance Optimization / Macro Transient Reduction File Size Assignment
During a thermo-mechanical analysis, it is necessary to transfer the heat transfer results to the mechanical analysis. This was done initially by specifying the cards (computed increments). It is now possible to enter the time range for this transfer, which makes the chaining independent of the heat transfer computation (that is the number of cards). Moreover, it is possible to transfer only the minimum thermal history data for each mechanical stage, leading to a significant improvement in performance.
SYSWELD DMP Performance Optimization / A New Label OPTIMIZE for the Fusion
The DMP FUSION command is used to rebuild transient and history files of the whole model by merging files of sub-domains saved by each process. The resulting transient and history files of the whole model were stored as temporary files and saved at the end on the disk. This sequence has been optimized. In order to reduce time spent for such solver operation, a new OPTIMIZE label has been added in the new SYSWELD version. With this label on the DMP FUSION command line, the resulting transient and history files are directly saved on disk. There are no more temporary files, leading to a significant improvement of performance.
8 processors / 1192 Cards - SYSWELD DMP 2011: 1936s - SYSWELD DMP 2012: 1058s - Factor: 2
SYSWELD SOLVER SYSWELD Solving Large Models
SYSWELD DMP Performance Optimization / Positive Definite MATRIX

For most kinds of simulation the global matrix is positive definite. In this case, the POSITIVE DEFINITE option can reduce the numerical factorization computing time to about 25%. METHODE MUMPS POSITIVE DEFINITE This option is not compatible with Lagrange Multiplier method.
SYSWELD DMP Capabilities Enhancement / Usage of Non-Conform Mesh via the REMESH Routine
The meshing operation is still a difficult task today, especially when the geometry of the structure is complex. The user has to spend a lot of time to create the mesh compared to the model set-up and computation time with the DMP version. Consequently, it is very important to reduce the meshing time. One solution is to use a standard structural analysis mesh and to refine the mesh along the weld line with a specific function and with the management of non-conforming shell and solid finite element automatically. The routine REMESH is an automatic mesh cutter that can be applied to any type of coherent mesh [cf. 6.3.9 Analysis Reference Manual]. The nature of the subdivision is defined by a function describing a map of element size. The routine modifies the mesh topology and manages the material properties and boundary condition of the modeled structure as well. The mesh is considered to be coherent if it has no discontinuity. The mesh cutter creates nodes that are adjacent to an element and consequently those nodes are not connected. Such a mesh is called a non-conforming mesh. Relations have to be created between the nodes on the border of the refined area to ensure the displacement field continuity. These relations are imposed with some specific transition elements automatically created be the routine REMESH. The main advantage of such a function is that the user can use a quite coarse mesh that does not fit the mesh discretization needed for welding simulation and refines automatically the mesh by applying several levels of re-meshing in the area where the weld joint are located. This functionality already exists in the previous versions of SYSWELD but has been extended so that it can be used for DMP (Distributed Memory Computation) on several processors. The management of the sub-domain partitioning has been improved to offer the possibility for the user to use such non-conforming meshes with transition elements during a DMP computation.
This functionality is available for the shell and solid option as it is illustrated in the figures below:
Temperature profile on solid and shell non-conform mesh
Elements Type 9 (X9XX) available for DMP

Shell/Solid Transition Element (29XX, SHAPE= 1 or 11)
They can be defined under DEFINITION procedure or created automatically with the COMPATIBILITY command. The element codes are the following: 2903 to connect a linear shell element using penalty method (SHAPE 1). 2904 to connect a quadratic shell element using penalty method (SHAPE 1). 2904 to connect a linear shell element using Lagrange multipliers method (SHAPE 11). 2905 to connect a quadratic shell element using Lagrange multipliers method (SHAPE 11).
Beam/Solid Transition Elements (29XX, SHAPE= 2 or 12) available for DMP
These elements can be defined under DEFINITION procedure or created automatically with the COMPATIBILITY command. The element codes are the following: 2905 and 2909 to connect linear solid elements to a beam element using penalty method (SHAPE 2). 2906 and 2910 to connect linear solid elements to a beam element using Lagrange multipliers method (SHAPE 12).
Transition Elements (X9XX, SHAPE= 3 or 13) available for DMP
These elements are used to constrain a node to be projected on an element. In practice, they can be used to connect a refined mesh to a coarse mesh or to connect linear elements to quadratic elements. The element codes are the following: 1903 to connect a node to an edge using penalty method (SHAPE 3) 2905 to connect a node to a face using penalty method (SHAPE 3) 1904 to connect a node to an edge using Lagrange multipliers method (SHAPE 13) 2906 to connect a node to a face using Lagrange multipliers method (SHAPE 13)
The PROPORTIONAL label is also available for SHAPE 3 elements.
10
SYSWELD DMP Capabilities Enhancement / Sub Domain Management
Subdomain partitioning management
The DMP PARTITIONING command has been modified to be as flexible as possible: The first option allows defining the partition using some groups that have already been defined: the name of such groups is prescribed: SYSDMP_ELEM_OF_PART_i with 1 i N where N is the total number of process. If the groups SYSDMP_ELEM_OF_PART_i exist before executing the DMP PARTITION command, they are kept. In the previous version, they were destroyed and recreated. If one or more SYSDMP_ELEM_OF_PART_i group is already defined but doesn't contain all elements of the mesh (figure 3a), the remaining elements are distributed among the existing partitions.
11
Mesh partitioning when one "SYSDMP_ELEM_OF_PART_i" group exists before DMP PARTITIONING command execution.
The second option is to define groups named SYSDMP_SUBMESH_TO_SHARE_"i" which will be partitioned independently in N partitions and then stored in the partitions. Thus, the partitions SYSDMP_ELEM_OF_PART_"j" gather all parts number j of all SYSDMP_SUBMESH_TO_SHARE_"i" groups and part number j of the rest of the mesh. In Figure 2 there is only one group SYSDMP_ELEM_OF_PART_1.
Figure 2: Example of DMP PARTITIONING command with and without SYSDMP_ SUBMESH_TO_SHARE_"i" element group
12
With this option, it is possible to handle the case when there are many elements without material. For example, if there is no material on white elements of Figure 2.b.1), and if material behavior is defined for grey elements, with the group SUBMESH_TO_SHARE_1 of the Figure 2.b.1) several elements with a material will be defined in each sub-domain. This is not the case on Figure 2.a.2) where the second sub-domain has no material and will lead to an issue during the computing in DMP. Note that it is also possible to solve this case using the following option. Finally, the last option is to define a weighting factor to each element of the mesh. With this option, the partitioning method balances the total weight of partitions. If no material behavior is defined on an element, its weight equals zero. Figure 3 shows the partitioning produced using the WEIGHT label as there is no material on white elements.
Figure 3: The DMP PARTITIONING WEIGHT command with no material behavior on a part of the mesh on Figure 3.b) there is approximately the same number of elements with a material in each partition.
13
SYSWELD DMP CAPABILITIES ENHANCEMENT DMP / COMPUTATION OPTION WITH CONTACT

The SYSWELD DMP solver has been extended to allow the user to perform mechanical contact simulation with the contact elements of type 6 (Two nodes element 1602) and 9 (Slide Plane).
Special Contact Elements (Slide-plane) type 9 level 1

The "LEVEL 2" option is incompatible with DMP computation today. Slide plane elements are used to model the 3D contact between deformable solids. The PROPORTIONAL label can also be used.
Special Constraint and Contact Element Type 6

The purpose of this element is to apply a linear or non-linear relation between the same degrees of freedom of two nodes. This can be used to simulate complex mechanisms comprising springs, dampers and contact. The PROPRTIONAL and TF labels are functional. The element code is 1602.
SYSWELD SOLVER SYSWELD DMP Capabilities Enhancement DMP / Computation Option with Contact
14
15
16
Spot Weld Advisor Contact Performance Improvement

The robustness of spot welding simulation tool has been improved to get accurate displacements in contact areas of the molten zone, even in case of large distortion.
Displacements computed with the new version of the spot welding tool.
17
END TO END CAST-WELD CHAINING SIMULATION / CAST-WELD INTERFACE

A new chaining between Pro-CAST and SYSWELD is available at the expert level. The interface allows transferring the thermal results (temperature field) and the mechanical results (residual stresses and strain) from Pro-CAST to SYSWELD. Thus, it is possible to account for residual stresses and distortions due to the casting in subsequent welding operations.
Automatic Light Post Processing during Computation

The post-processing of very large models can be tedious due to the size of the POST file. It is now possible to store only the element value (center) in this file leading to a much smaller POST file size and consequently, much faster visualization.
SYSWELD SOLVER End to End Cast-Weld Chaining Simulation / Cast-Weld Interface
19
VISUAL-WELD AND VISUAL HEAT TREATMENT

VISUAL-WELD
General Description
The Welding Advisor is an easy-to-use work-flow based interface that allows you to set up Single-Pass and few Multi-Pass Welding simulations. The complete work-flow is represented as different steps and you are guided to complete the set up with minimum input.
Multiple Database Support

You can assign materials to components by choosing the material from a wide range of material database files (*.mat). Visual-WELD generates a new .mat file with all materials selected from the database files. In a similar way, you can assign functions by choosing them from a wide range of function database files (*.fct).
VISUAL-WELD AND VISUAL HEAT TREATMENT Visual-WELD
20
Direct .DAT File Loading

Any valid *.DAT file can be loaded directly into Visual-WELD. This facility allows you to load the DAT file which is generated in SYSWELD or any other tool. You can modify the card data directly and export as a *.ASC file. This file can be used in Computation Manager. A log file is generated and posted as a hyperlink on the console for your information.
Remark:
The computation manager works with the previously generated ASCII files and the *_C.DAT thermal and the mechanical files. If any PROJECT_NAME_HT.DAT and PROJECT_NAME_MECH.DAT files have been modified, it is necessary, to generate the ASCII file before to launch the computation manager to take into account the modification. .For this purpose it is then needed to load in Visual-WELD the following GENERATE_ASCII_FILES.DAT file. Then all the ACSII files will be generated and will be used by the computation manager automatically.
VISUAL-WELD AND VISUAL HEAT TREATMENT Visual-WELD
21
VISUAL-HEAT TREATMENT
General Description
The Heat Treatment Advisor is an easy-to-use workflow based interface that allows you to set up heat treatment simulations. The complete workflow is represented as different steps and you are efficiently guided to complete the set up with minimum input.
Project Description
In this step, you can define the project name and working directory along with other basic information for project identification. The project name will be used for all the files created and the working directory will be used as a repository for all these files.
VISUAL-WELD AND VISUAL HEAT TREATMENT Visual-Heat Treatment
22
Process Definition
You can select required Heating, Carburizing, and Quenching processes for heat treatment. Tempering is not yet supported. Computation options are set automatically: two dimensional (2D translation), axisymmetric (2D rotational) or three-dimensional (SOLIDS). For 3D option, you can also use the cyclic symmetry methodology. Elements with linear or quadratic shape function are valid.
23
Material Properties
It is necessary to assign specific material data for both the thermo-metallurgical and the mechanical analysis. This assignment of properties is carried out by entering the Material class and the material name, which exist in the loaded material database. The button brings up the Choice of a material, from which a material can be loaded.
Heat Treatment Process (Heating/Carburization/Quenching)

You can define heating conditions before or after quenching process. The Carburization process allows you to define the imposed temperature and the imposed carbon activity for given points in time.
24
The quenching media is used as a surface boundary condition. It is assigned to surfaces of the part where heat is exchanged with the surroundings. The heat exchange regions may be defined. You can also define quench media with diving by defining the immersion starting time, the velocity and the heat exchange between the part and the air.
25
Clamping Condition
You can define all clamping conditions required for complete welding to take place in this step. First define all clamps to be used: they can be Elastic, Rigid, Symmetry or Unclamped. Then, you should define the clamping sequence as for example. Each clamping condition will be applied from the initial time to the end time. The unclamping condition may be defined as well.
26
Loads and Deformations

You can define all loading conditions in step 7. As with the clamping conditions previously defined, all the load and the deformation conditions may be defined.
27
Solution Parameters
You can set various solver parameters, including Analysis type, Initial temperature, *.par files to use, disk space option, etc., in this step.
A few more useful features are listed below. Advisor.
You can go to Explorer or Part Table at any time from Heat Treatment Right-click edit or double click on the Explorer sub-folders will automatically take you to the corresponding process block in the Heat Treatment Advisor. Complete GUI is multi-model / multi-window compatible. All user actions are saved in vsession.py file, which can be replayed. Models can be saved in .vdb format, which saves complete information of the model.
28
WELD-HT CHAINING SOLUTION

With this new version it is now possible to chain the welding and the heat treatment simulations. Heat Treatment project files are restarted if welding project files already exist in the current working directory. An option is given to select Weld - HT chaining or normal heat treatment export. The start time of the heat treatment project files is the end time of the last welding project file.
VISUAL-WELD AND VISUAL HEAT TREATMENT Weld-HT Chaining Solution
29
COMPUTATION MANAGER
General Description
Computation Manager is an easy-to-use utility that allows you to manage complex simulations in an efficient way. It gives you an overview of the contents of the selected project and allows you to control the simulations that you wish to run. The key features are listed below. Based on the <project>.vdb selected, all the <project>.prj files are automatically selected and listed in the table Option to select required step is provided Color coding of cells is done based on the solver status. Gray: No computation Blue: Computation running Orange: Problem during computation Green: Computation done
Option to view LOG file is provided for files of all steps by clicking the button.
Computation Manager
VISUAL-WELD AND VISUAL HEAT TREATMENT Computation Manager
30
DMP Performance
Improved performance of DMP solver for faster computation without neglecting material physics.
DMP Selection
Export for Cluster

This feature allows you to export all the data files through the Computation Manager to solve large models on a Linux cluster.
VISUAL-WELD AND VISUAL HEAT TREATMENT Computation Manager
31
VISUAL-VIEWER 7.6
LOCATION SUPPORTS FRAME
With the new version of Visual-Viewer you can compare the results computed directly with measured data one, even if these measured data are defined in a specific local coordinate system. You define the new local frame coordinate system which corresponds to the experimental one and all results are automatically rotated and transformed to facilitate the comparison.
Location Supports Frame Panel
VISUAL-VIEWER 7.6 Location Supports Frame
32
VISUAL-VIEWER 7.6 Location Supports Frame
33
WELD PLANNER
MANAGEMENT OF 3D MODEL
In Assemblies made of heavy plates withsmaller ratios of surface to volume, shell models are not as effective. To solve this problem, the shrinkage method using solid elements has been implemented inthe new version of WELD PLANNER. The solid elements supported are tetrahedron and hexahedron. In order to define a weld assembly simulation in WELD PLANNER on a 3D model it is helpful to define all the collectors needed for the definition of the material properties, the clamping conditions and the welds . This can be done in Visual-Mesh 7.5.
WELD PLANNER Management of 3D Model
34
As indicated in the following figures, a comparison has been performed on typical Tjoint configuration. On the left side, the distortion results of full transient thermal metallurgical and mechanical simulation is displayed, while on the right side, the distortion is based on the 3D shrinkage methodology. Applying shrinkage in one step will not deliver start and end effects; but the transient simulation compares well to the same level of the distortion computed with the shrinkage method.
Figure 1 Full transient (displacements)
Figure 2 3D Shrinkage (displacements)
WELD PLANNER Management of 3D Model
35
SPOT WELD SIMULATION

With the new version of the WELD PLANNER, you can set up a spot weld assembly simulation. You define the groups of nodes on one component where the spot weld must be located. All necessary collectors can be defined with Visual-Mesh 7.5.
Based on this information, WELD PLANNER will automatically associate the different components that will be spot welded and will create the connector elements to simulate the spot weld connection and apply the thermal shrinkage.
WELD PLANNER Spot Weld Simulation
36
37
38
Rigid and Elastic Clamping Condition in Local Frame

During a welding assembly simulation, rigid clamping conditions are too restrictive and are applied only on the global frame. With the new version of the WELD PLANNER, you can apply Rigid or Elastic clamping condition in theglobal or local coordinate system.
39
Release Step Improvement of Very Large Model

For specific configurations, like very large flimsy components, the release step should be incremental; otherwise some convergence problems can occur. The methodology has been implemented inside the new version of WELD PLANNER in order to avoid any convergence issue on flimsy models during this release step.
Management of Very Large Model Through the Graphic User Interface

The Graphic user interface of the WELD PLANNER has been strongly improved to allow you to easier and faster import, display and manipulate very large models.
41
MATERIAL DATA MANAGEMENT

PHASE TRANSFORMATION CALIBRATION MANAGER (PTCM)
Based on the chemical composition or continuous CCT or isothermal TTT experimental diagrams, the specific mathematical law implemented in SYSWELD to simulate all phases transformation can be automatically calibrated with PTCM tool in only a few minutes. For more information on how to use this tool please refer to the training material available in the training and tool box CDROM 2012.
MATERIAL DATA MANAGEMENT Phase Transformation Calibration Manager (PTCM)
42
MATERIAL DATA MANAGEMENT Phase Transformation Calibration Manager (PTCM)
43
STRAIN HARDENING CALIBRATION TOOL

A fast calibration of yield strength and strain hardening based on measured material parameters or WELDWARE input data are available today. It allows computation of yield strength that is dependent on the modulus of elasticity and approximates the strain hardening curve by use of the simplified Ramberg-Osgood equation. This tool is fully compatible with the Material Data Manager. For more information on how to use this tool please refer to the training material available in the training and tool box CD Rom 2012.
MATERIAL DATA MANAGEMENT Strain Hardening Calibration Tool
44
MATERIAL DATA MANAGER V3.4

The material data manager allows all calibrated material data to be gathered. Thermophysical properties of all steel classes are included. You can import and export any SYSWELD material database (*.mat) and METALLURGY.DAT file. These material databases can be split or merged. The Material data Manager integrates Richter steel database and interfaces to the Strain-Hardening Tool (SHT) and the Stress Strain Calibration Manager (SSCM). For further information on how to use this tool please refer to the training material available in the training and tool box CD Rom 2012.
MATERIAL DATA MANAGEMENT Material Data Manager V3.4
45
INTERFACE WITH WELDWARE

WeldWare is a modular welding advisory system that aides the calculation of heat procedures in welding. The Weldweare output is taken as input for distortion, weld quality and residual stress analysis on complex structures. WeldWare allows the determination of heat input and pre-heat temperature for the best weld quality. The heat input module works for unalloyed steels, high alloyed steels, aluminum, titanium and nickel alloys. For more information on how to use this tool please refer to the training material available in the training and tool box CDROM 2012. WeldWare is a product from SLV M-V GmbH Rostock / Germany. It works well together with the ESI Welding Suite.
Based on the chemical composition, a welding CCT diagram and the microstructure for a typical cooling rate can be computed.
MATERIAL DATA MANAGEMENT Interface with WELDWARE
46
Based on the chemical composition, mechanical properties can be computed for typical cooling rates. The mixture of base and wire material can be computed for carbon or low alloyed steels. Based on the new chemical composition further analysis can be performed.
47
It is today possible to export all this data for the generation of a specific SYSWELD material database. A specific interface with WELDWARE has been developed for this purpose. All the data exported can be imported by the Phase Transformation Calibration Manager (PTCM) and the Stress Strain curve Calibration Manager.
48

Welding Simulation Suite 2012

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Welding Simulation Suite 2012

Uploaded by

Copyright:

Available Formats

Insert the front cover image in this header, then position and resize it !

WELDING SIMULATION SUITE 2012

WELDING SIMULATION SUITE 2012

2012 ESI Group. All rights reserved.

WELDING SIMULATION SUITE 2012 2012 ESI Group

RELEASE NOTES (released: Jan-12)

VISUAL-WELD AND VISUAL HEAT TREATMENT ......... 19

Weld-HT Chaining Solution ...................................................................... 28 Computation Manager .............................................................................. 29

VISUAL-VIEWER 7.6 ........................................................ 31

Location Supports Frame ......................................................................... 31

RELEASE NOTES (released: Jan-12)

WELDING SIMULATION SUITE 2012 2012 ESI Group

WELD PLANNER .............................................................. 33

Management of 3D Model ........................................................................ 33 Spot Weld Simulation ............................................................................... 35

MATERIAL DATA MANAGEMENT .................................. 41

WELDING SIMULATION SUITE 2012 2012 ESI Group

RELEASE NOTES (released: Jan-12)

WELDING SIMULATION SUITE

WELDING SIMULATION SUITE SYSWELD Improve Fatigue Performance

RELEASE NOTES (released: Jan-12)

WELDING SIMULATION SUITE 2012 2012 ESI Group

WELDING SIMULATION SUITE SYSWELD Improve Fatigue Performance

WELDING SIMULATION SUITE 2012 2012 ESI Group

RELEASE NOTES (released: Jan-12)

SYSWELD SOLVER SYSWELD Improve Fatigue Performance

RELEASE NOTES (released: Jan-12)

WELDING SIMULATION SUITE 2012 2012 ESI Group

reversed bending (fatigue limit

SYSWELD SOLVER SYSWELD Improve Fatigue Performance

WELDING SIMULATION SUITE 2012 2012 ESI Group

RELEASE NOTES (released: Jan-12)

Dang Van Criteria output Post Processing (Courtesy PSA)

SYSWELD SOLVER SYSWELD Improve Fatigue Performance

RELEASE NOTES (released: Jan-12)

WELDING SIMULATION SUITE 2012 2012 ESI Group

SYSWELD SOLVING LARGE MODELS

SYSWELD SOLVER SYSWELD Solving Large Models

WELDING SIMULATION SUITE 2012 2012 ESI Group

RELEASE NOTES (released: Jan-12)

SYSWELD DMP Performance Optimization / Positive Definite MATRIX

SYSWELD SOLVER SYSWELD Solving Large Models

RELEASE NOTES (released: Jan-12)

WELDING SIMULATION SUITE 2012 2012 ESI Group

Temperature profile on solid and shell non-conform mesh

SYSWELD SOLVER SYSWELD Solving Large Models

WELDING SIMULATION SUITE 2012 2012 ESI Group

RELEASE NOTES (released: Jan-12)

Elements Type 9 (X9XX) available for DMP

Beam/Solid Transition Elements (29XX, SHAPE= 2 or 12) available for DMP

Transition Elements (X9XX, SHAPE= 3 or 13) available for DMP

The PROPORTIONAL label is also available for SHAPE 3 elements.

SYSWELD SOLVER SYSWELD Solving Large Models

RELEASE NOTES (released: Jan-12)

WELDING SIMULATION SUITE 2012 2012 ESI Group

SYSWELD DMP Capabilities Enhancement / Sub Domain Management

Subdomain partitioning management

SYSWELD SOLVER SYSWELD Solving Large Models

WELDING SIMULATION SUITE 2012 2012 ESI Group

RELEASE NOTES (released: Jan-12)

SYSWELD SOLVER SYSWELD Solving Large Models

RELEASE NOTES (released: Jan-12)

WELDING SIMULATION SUITE 2012 2012 ESI Group

SYSWELD SOLVER SYSWELD Solving Large Models

WELDING SIMULATION SUITE 2012 2012 ESI Group