Graphical User Interface

Modeling, simulation, and evaluation from a single user interface

Simufact Welding comes with a single graphical user interface providing comprehensive functionality for all simulation steps from modeling to calculation and the evaluation of results.

 

Modeling Highlights:

  • Applicable for all common thermal joining processes, like arc and beam welding and brazing, as well as resistance spot welding, heat treatment and cooling and clamping
  • Scalable simulation approach allowing quick estimation of results
  • Automatic definition of torch and laser incidence angles relative to components in a global or local coordinate system (without manual definition of reference lines)
  • Preview of heat sources and weld paths including orientation and time-dependent positions
  • Welding parameter library helps to connect modeled heat sources with real processes
  • Automatic calculation of orientation of electrodes
  • Automatic mesh refinement and coarsening (no need to use user subroutines)
  • Non-congruent meshes for components and fillets are allowed
  • Automatic detection of contacts and consideration of friction
  • Clamps can be defined using their real geometry
  • Automatic consideration of heat losses due to radiation and convection (no manual definition of surface meshes)
  • Pre-State functionality provides the possibility of importing previous results (from Simufact.forming or Simufact.welding) from the GUI. This allows for calculations of assemblies and process chains.
  • The definition of “Local Joints” allows a direct connection of two components with each other (this provides the possibility of modeling of influences of spot welding, mechanical joining, or tack welds on stiffness of the assembly)
  • The fillet generator creates elements of a hollow weld
  • Automatic projection of weld path on the surface of weld seam
  • Manual calibration of heat fluxes is unnecessary to ensure a constant energy input over time
  • User-defined unit systems with automatic conversion reduce mistakes due to wrong input and output evaluation
  • Process sequences including cooling and unclamping can be presented as a Gantt-diagram
  • Flexible positioning of geometries of the assembly and fixture
  • Fixtures can be imported from CAD data
  • Each clamping tool as well as bearing can be removed after a predefined time
  • Simplified adaptation of database-based material data to real material properties results in high precision when it comes to the prediction of residual stresses and thereby to evaluation of distortions and effects of recovery
  • Material models support phase transformations occurring in steels during welding
  • Advanced settings allows in depth control of convergence criteria, time stepping and contact definition

Evaluation of Results - Highlights:

  • Definition of local coordinate systems including cylindrical
  • Visualization of melt pool and heat affected zone as a cross-section
  • Export of multi-stage videos (avi-format) based on increment number or process time
  • Definition of custom results variables using mathematical and logical operators
  • Results management allows a direct visualization of calculated increments (single result files for each component and increment)
  • Export of results into the Universal File Format (unv-format) which is supported by current finite element software.
  • Smooth visualization of large models including results several terabytes of data
  • Export and visualization of results as X-Y-Plots
  • Export and visualization of forces and displacements experienced by clamping tools

Calculation Highlights:

  • Definition of contacts considers the residual stress situation of press-fitted components in the initial state
  • Calculation of gap development if clamps are not sufficient
  • Activation of fillet elements by a moving heat source
  • Flow curves can be defined with respect to temperature and peak temperature. This allows the consideration of effects of precipitation and dilution
  • Hardness and tensile strength can be evaluated as a function of t8/5 times
  • Solver can be used in Windows and Linux environment
  • DDM and SMP parallelization speeds up calculations of large assemblies
  • Node-to-segment and segment-to-segment contact provide the right contact formulation for a huge variety of contact problems

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