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 t_8/5 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

Example of stress-strain curves defined with respect to peak temperature

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