Top key features of the previous Simufact Welding versions

Do you want to know which key features we have implemented in the previous versions? Familiarize yourself with the top new key features of each respective versions. Please note that we only provide the key features for the last three versions.

Top new features in Simufact Welding 8

 

 

Simufact Welding 8 Release Updates
  • Meshing technology from a single source
  • Increased meshing quality and calculation stability through improved fillet generator
  • ...

Meshing technology from a single source

Simufact Welding 8 offers Simufact’s own embedded meshing technology which usage is user-friendly and intuitive. Users can create basic geometries directly in Simufact Welding and mesh them with internal meshers that support hexahedral and tetrahedral elements as well as solid shells. The meshing technology also supports local refinement boxes, allowing to create denser meshes in weld seams or weld spots. It makes the daily work of a welding specialist more comfortable. Simufact users become advantage of the wide product range of MSC Software: Creation of large and complex models is supported by the companies owned mesher of MSC Software. Customers do not need to use third-party products for meshing large, complex welding models.

Abb. Screenshot: Meshing technology from one single source
Meshing technology from one single source

Increased meshing quality and calculation stability through improved fillet generator

Simufact Welding 8 comes along with a widely reworked fillet generator which is now able to create meshed geometries based on quadrangular shapes including groove welds, plug welds, bead-on plate, etc.  Triangle-based fillets can now be created with respect to given (uneven) leg lengths, so that the number of nodes per leg corresponds with the relation of leg length. Additionally, created mesh cross-section are visible in the generator preview window, so the mesh quality can be controlled directly here without the need to create and control meshes afterwards. This leads to better mesh quality and improves the calculation stability and also quality of results.

App. Screenshot: Newly reworked fillet generator
Newly reworked fillet generator

Reduce time while creating complex assemblies with a large number of tools

The recently released version of Simufact Welding 8 offers more realistic clamping tools. During the simulation clamps can be activated, deactivated or fixed in space for a certain time period. The transfer of clamp properties, such as activation or fixation time, forces, stiffness, as well as the extended creation wizard reduce the effort needed to create and configure large numbers of tools with similar properties. Especially for complex assemblies with high number of tools those new features reduce the time needed for proper model setup.

App: Screenshot: Handle complex assemblies
Handle complex assemblies

Intuitive and easy model setup by automatic gravity positioning and bounding box alignment

These both new features make the model setup more intuitive and make positioning of components in the model easier. Using gravity positioner Simufact Welding 8 is able to automatically calculate the behavior of a geometry falling onto other geometries under the influence of gravity. The calculation includes friction and damping and furthermore the user also controls the precision of the calculation. The bounding box positioner allows easy positioning of geometries relative to each other. From the user’s perspective, it is a usability improvement which largely reduces the time needed for preprocessing.

App: Screenshot: Easy and intutive model set up
Easy and intutive model set up

Extended and improved functionality for the import and export of UNV-files

Simufact Welding 8 offers in its graphical interface an extended and improved functionality for the import and the export of UNV-files. Users are now more flexible while importing files from third-party products. Even if imported files are not following the UNV standard definition or include some user defined result types, import settings can now be edited and configured before importing the UNV-files into a Simufact Welding project. The new version also offers new functions for exporting UNV-files: Users can now decide if they only want to view the files in a third-party product or if they want to use them for subsequent steps such as structural analysis or NVH-analysis, in this case, results needed for further calculation are exported in integration points and can be used for following analysis steps.

App. Screenshot: Extended and improved UNV-files import
Extended and improved UNV-files import

New interactive model and result views increase the usability of the user interface

The latest version of Simufact Welding provides an interactive view control widget in model and result views. The widget combines the functionality for view control (view angles, zoom, mirroring, rotations, reset to defaults) as well as view synchronization (synchronizing several views open in one project). Also, the synchronization now supports live synchronization, automatically changing view settings, result type and selected increment in all open views if those settings are changed by the user in one of the open views. Using the widget enables the user to work faster and more efficiently while evaluating the results of the simulation, comparing different models and their results. In addition, the representation of geometries in the view (mesh, solid, contours and so on) is now controllable for the complete model as well as for single geometry.

App: Screenshot: Interactive model and result views
Interactive model and result views

Best-Fit method: By touch of a button compare simulation and reference model

In Simufact Welding 8, users can easily compare the simulated model with a reference model (e.g. a CAD model or measured surfaces) using the “best-fit method”. In the best-fit-method the software automatically determines the position at which the deviation between both geometries is the lowest and shows this deviation in the result view. The visual presentation of the results, based on measurements, allows the user quickly assess whether the deviations are within the permissible tolerances. For this function, Simufact has integrated Hexagon’s 3DReshaper technology.

Screenshot: Best-Fit method - Compare simulation and reference model
Best-Fit method - Compare simulation and reference model

Proper import of result files from clouds or other remote high-performance machines

Cloud computing and HPC (high performance computing) is often used for the simulation of various numbers of models. In such cases the data needed by the solver is sent to a remote machine, where the calculation takes place. Simufact Welding 8 is now able to import result files in the GUI, sort them properly and make them available for the result evaluation.

App: Screenshot: Proper import of HPC-results
Proper import of HPC-results

Simufact Welding 7 Release Updates

Button Simufact Welding V7

 

Simufact Welding 7 Release Updates
  • Faster calculation of thin-walled sheet metal parts by solid-shell elements
  • ...

Top 10 novelties in Simufact Welding 7

Faster calculation of thin-walled sheet metal parts by solid-shell elements

Through the use of solid shell elements, assemblies made of thin sheets require less calculation time because the required number of elements in the model drops significantly.

The software can also convert many models with hexahedron elements into solid-shell meshes. To do this, Simufact Welding 7 checks whether clear upper and lower surfaces are present. If these specifications are identified by the conversion function, the previous hexahedron mesh can be converted to solid-shell mesh.

Faster calculation of thin-walled sheet metal parts by solid-shell meshing
Faster calculation of thin-walled sheet metal parts by solid-shell meshing

Faster and more efficient calculation of large models

The parallel segment-to-segment calculation implemented in the new solver allows faster and more efficient calculation of large models with many contact surfaces. This contact description uses DDM (Domain Decomposition Method) a parallel computation framework which utilized parallel computation efficiently.

New solver and revised contact definition accelerate the simulation
New solver and revised contact definition accelerate the simulation

Shorter calculation time for resistance spot welding processes

In Simufact Welding 7, Simufact introduces the simplified calculation method “Thermal Cycle” for resistance spot welding processes. This method, which is already used for other welding processes, complex and large assemblies can be calculated in a shorter computing time.

If the shape of the nugget  is for example already known from process models or measurements, the user can additionally simplify the calculation by directly predefining temperatures in the nugget without previous calculation.

Simplified calculation methods for resistance spot welding processes
Simplified calculation methods for resistance spot welding processes

Simplify the model set-up with Robot assistant

With a few mouse clicks, users can add new welding robots with multiple welding paths, heat sources and fillet seams to their models. This is useful when the user is confronted with many welds while simulating large structures or multi-part assemblies. The robot assistant simplifies the model set up for the user, since it can process all definition steps in one dialogue.

Robot assistant simplifies the model set-up
Robot assistant simplifies the model set-up

Automatic detection of edges with node sequences for faster model set-up

This new feature automatically detects the edges of a component. The automatic edge detection simplifies the work on the model and helps to avoid errors when creating welding paths on curved surfaces and edges. On top, users can create complex welding paths much easier.

Node sequences can be directly selected and extended
Node sequences can be directly selected and extended

Practical oriented 3D measurement for a better validation of simulation results

Users compare their simulated model with their target design or with 3D measurement data as a reference model. They import the reference model from the measurement software into the user interface of Simufact Welding 7 and can then compare the simulated workpiece with the target design. If the engineers overlap both workpieces, they can determine the deformation. This shows the deviation between the simulated and the target design. A further functionality allows the definition of local coordinate systems by:

  • 3-2-1 plane
  • 3 points
  • Measuring table
  • Cylindrical coordinate system
Improved result transformation - Validation of simulation results
Improved result transformation - Validation of simulation results

Fast alignment of components

Using the transformation matrix, engineers can position and move the workpieces quickly and individually in the software. The user can position the same workpiece independently in several models. Contact positioner allows fast alignment of components to each other. In this way, the user saves time since manual corrections are no longer required.

Individual positioning with the contact positioner and with the transformation matrix
Individual positioning with the contact positioner and with the transformation matrix

Increased quality of resistance spot welding simulation by adding additional coating data

The material properties influence the result quality of resistance spot welding processes by the resistances in the material. Simufact Welding 7 contains 16 common coatings, which enable the user to take into account the electrical properties of coated sheets and to further increase the quality of the simulation. No effort is required to determine the resistance data.

Additional coating data are added to the database for resistance spot welding processes
Additional coating data are added to the database for resistance spot welding processes

Improved compatibility of Simufact Welding by incorporating UNV files

Depicting the process chain
Depicting the process chain

Simufact Welding 7 can import UNV files - improving the compatibility of the welding software with third-party software and interoperability in the process chain. The user can import result data from third parties such as from forming or casting simulation into Simufact Welding in order to edit these files or use them for subsequent calculations.

Definition of clamping tools with translational and rotational stiffness

While welding large assemblies, usually several hundred clamping tools are required, which, like the welding itself, have an influence on distortions and residual stresses on the assembly. Until now, the stiffness in the clamp could be described exclusively perpendicular to the contact surface. With the implementation of the definition of clamping tools with translatory and rotational stiffness, version 7 additionally takes into account possible rotations and the movements of the tools along the surface.

Definition of clamping tools with translational and rotational stiffness
Definition of clamping tools with translational and rotational stiffness

Simufact Welding 6 Release Updates

Button Simufact Welding V6

 

Simufact Welding 6 Release Updates
  • Reduced calculation times - Improved evaluation of results
  • Post-Particle Tracking
  • Time-History-Plot
  • ...

Simufact Welding 6 Release Updates

View of the quay shipyard at sunrise in Gdansk, Poland (Source: fotolia)
View of the quay shipyard at sunrise in Gdansk, Poland (Source: fotolia)

Reduced calculation times - Improved evaluation of results

Simufact Welding 6 puts a focus on reducing calculation times and enhanced options for the evaluation of simulation results (post processing).

Simufact Welding 6 fulfils the request for obtaining precise simulation result within a short calculation time. The software offers scalable calculation methods for various tasks regarding the accuracy and simulation speed. Through the introduction of further simplified calculation methods, Simufact Welding can now also be used to simulate simultaneously, several longer processes with multiple welds and several welding points.

Extensive changes in the solver have contributed to a significant improvement in the stability and speed of the simulation.

New functions make it easier for the user to evaluate the simulation results (post processing):

 

 

Post-Particle Tracking

Post-Particle Tracking allows the user to customize the measuring point settings, after a comparison of the simulation results with the measurement data, thus the model optimization can be done much easier and faster.

Time-History-Plot

During the welding process the engineer can measure and evaluate the forces on the clamping tools with the help of the Time-History-Plot function. The measurements given by this function, provide the engineer with information on the spanner-force distribution, tool displacement and other important information for the optimization of the clamping devices.

Enhancements Simufact Welding 6:

  • Simplified automated modelling allow for the computation of large-scale assemblies within a finite time.
  • Significantly higher level of stability and speed of simulation due to comprehensive changes in the solver
  • Introduction of post particles and THS plots
  • Introduction of Pre-states with refinement options
  • Three new process types: splitting laser beams and electron beams,brazing, stress relief
  • Extensive improvements to the resistance spot welding simulator
  • Revision of the heat sources
  • Flexible temperature objects
  • Complete revision of the step control system
  • CAD import function for tools
    • Comprehensive revision of the modelling process and the results management, e.g.: the preview functions, revised the color coding, UNV export, heat source database, assemblies etc.

Simufact.welding 5 Release Information

Button Simufact Welding V5

 

Simufact.welding 5 Release Information
  • AFS Technology
  • Resistance Spot Welding with Simufact.welding
  • More efficient modelling through improved user-friendliness
  • ...
Simufact.welding 5 product box

Simufact.welding 5 is available

Simufact.welding 5 is more closely towards the real welding processes and comes with a new application module Resistance Spot Welding.

The cover of the new Simufact.welding 5 software box illustrates the simulation of a laser-welded gear wheel, carrier of an agricultural vehicle and a lower part of an axle.

 

AFS Technology

With Simufact.welding 5 Simufact determines the basis for the introduction of the already in Simufact.forming proven AFS technology (Application Function Sets). Thus the user can now also select in Simufact.welding a graphically appealing, initial selection of welding processes and types of application scenarios.

AFS Technology

With Simufact.welding 5 Simufact determines the basis for the introduction of the already in Simufact.forming proven AFS technology (Application Function Sets). Thus the user can now also select in Simufact.welding a graphically appealing, initial selection of welding processes and types of application scenarios.

Resistance Spot Welding with Simufact.welding

Simufact.welding 5 enables users to simulate resistance spot welding. The new version comes with a full electrical-thermal-metallurgical-mechanical coupled analysis. Based on that the influence of reheating and shunting effects can be modelled; electrical properties can be modelled phase-dependent. In particular the automotive manufacturing industry uses this welding process type. With Simufact.welding 5 we support the engineers in the approach.

More efficient modelling through improved user-friendliness

Apart from the introduction of process types, Simufact’s developers have made a number of improvements for the users of Simufact.welding 5. The Creation and Assignment Wizards for geometries, materials and marginal conditions allow for a faster and automated assignment of objects to the chosen processes.

Process optimization with Process Control Center (interactive Gantt diagram)

Simufact.welding employs Gantt diagrams to visualize process times. Gantt-diagrams are used in project management to visualize the time sequence of process steps as bars on a time axis. With Simufact.welding 5, a static Gantt diagram becomes an interactive Process Control Center (PCC), which can be used to optimize welding sequences, cooling and unclamping times.

 

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