Watch this promotional video and gain first insights into Simufact Welding fields of application, use cases, and GUI impressions.
The latest version of our welding simulation solution offers enormous improvements in the RSW Module.
Take part our four-part webinar series on welding structure simulation.
Our Simufact experts give you insights into the application areas and the potential of welding simulation software.
Simufact launched adedicated simulation solution for Direct Energy Deposition (DED).
Familiarize yourself with the the functionality of the software, we will show you the GUI and software usage.
Simufact Welding is designed for modeling and simulation of a wide range of thermal joining processes by means of structural welding simulation including usual arc and beam welding processes as well as brazing. Additionally, Simufact Welding provides possibilities to model heat treatment processes, variations of cooling and unclamping setups as well as mechanical loading of welded structures.
Simufact Welding benefits in a nutshell:
Very biefly: Gain time and safety in the design of your welding processes.
Employ Simufact Welding and ...
1. … identify critical distortions, i.e. with respect to assembly, bulging, imbalances, and clearances
2. … investigate and optimize clamping tools even before an investment in tools has been made
3. … identify optimal welding directions and welding sequences
4. … investigate the influence of unclamping on welding distortions and residual stresses
5. … gain knowledge about the development of the heat affected zone
6. … use a tool which supports you during planning of welding processes
7. … innovate your process design:
8. … verify the quality of welding seams, i.e. by calculating nugget sizes, brittle metallurgical phases, hardness, and effects of preheating.
In 2016, the German trade magazine MM MaschinenMarkt has honored the 'best of the best' with the high-ranking "Best of Industry" industry award.
Welding simulation in Simufact Welding uses the finite element method. This approach is especially suitable for calculation of elastic-plastic material behavior with hardening, thus being well suited for structural welding simulation. Complex processes during welding – induced by an arc or by evaporating metal inside a keyhole - are not taken into account. This means that process stability and weld seam geometry are not results of a simulation but input parameters.
Structural welding simulation calculates effects of heat input of the welding process from a mathematical description of heat flux during welding, namely, a description of the melt pool isothermal line by an equivalent heat source.
Complex process details such as the kind of the laser used or powder in a submerged welding process are neglected.
Structural welding simulation needs proper input data to calculate reliable results. The needed data includes:
Many of the over 150 existing welding processes can be investigated by Simufact Welding.
One of the most relevant welding processes is Resistance Spot Welding (RSW), a widely used process in automotive assembly and general sheet metal working. For RSW simulation, Simufact Welding covers both aspects: the simulation of structural welding as well as the simulation of the welding process.
Structural welding simulation uses the finite element method to calculate global and local impact of heat input on a welding assembly. Usual results are distortions, stresses and resulting material properties.
Structural welding simulation needs proper input data to calculate reliable results. The needed data includes:
Depending on the level of detail and data quality you are able to ...
Depending on the amount and quality of input data, Simufact Welding provides following results:
Simufact Welding also covers the simulation of Additive Manufacturing Laser Metal Deposition (LMD) processes, such as:
Direct Metal Deposition (DMD)
Direct Energy Deposition (DED)
Laser Cladding
Software capabilities allow for:
This video shows you the results of a laser deposition welding model of an additively made turbine blade.
Courtesy of Fraunhofer IPK
The advantages of the process include faster production times and manufacturability of larger components than other comparable Additive Manufacturing (AM) processes.
However, the deformation after the DED process is enormous due to the size of the parts and the energy input during the process. The result is that the final shape of the DED parts does not match with that of the design. FEM simulation allows the prediction of the final distortions and their compensation to obtain an optimised DED component. This saves costs, but computation time is still a major obstacle for industrial use.
Simufact Welding offers a powerful GUI supporting the user during all simulation steps:
Simufact Welding includes scalable simulation approaches for your individual needs and goals - available in one single GUI.
Your benefit: One single GUI for the entire simulation process, there is no need to skip between different software applications.
Simufact Welding provides a unique scaled simulation approach out of one GUI, scaling between detailed results, but rather slow calculation and coarse results, but fast calculation.
Your benefit:
The scalable approach gives you the flexibility to choose the right simulation approach for your individual sitation. For certain result quality the model complexity and the calculation time can be scaled between several weeks and few hours.
Simufact Welding is a modular software, subdivided into application modules providing welding process-specific functionality and additional modules providing material data and parallelization technology boosting simulation performance.
Core functionality is provided by the Welding Hub and its associated Thermal Joining application modules, offering the possibility of pre- and postprocessing as well as calculation of thermal joining processes. Additionally, a Resistance Spot Welding module is available. An optional bundle with MSC Apex Modeler provides CAD and meshing capabilities.
Standard modules include the capability of:
The capability of transferring simulation results from one manufacturing step to subsequent steps is a prerequisite for result accuracy in the entire simulation process chain.
In combination with Simufact Forming it is possible to model entire process chains, for instance forming processes on components that are welded in the next step and vice versa.
Data exchange between Simufact Forming and Simufact Welding allows for stepwise calculations that are based on previous results. This approach makes it possible to calculate welded assemblies, or to carry out process chain simulations.
Therefore it is possible to integrate welding with pre- and post-processing in a common numerical framework. The easy data transfer allows consideration of the material history with respect to a previous forming process, as well as the fatigue response of a calculated weldment.
Wheel rim, welded from the inside, temperature field
Wheel rim, welded from the inside, distortions
Welding of a bearer structure, temperature field
Von Mises equivalent stress
Maximal temperatures of a resistance spot welded connection between B-pillar and the roof frame
This video gives a brief introduction into welding simulation in joining and assembly with Simufact Welding. First part introduces the aims of Simufact Welding and in the second part offers insights into the practical side of Simufact Welding with different examples.
Webinar recording from August, 16th, 2017, held by Dr. Marius Gatzen
53:08 min
Challenge:
Through thermal energy metal is melted and creates a safe joint which in turn leads to a change in the micro-structure of the material in the heat affected-zones (HAZ) and can thus contribute unwanted failure mechanisms.
Solution:
By combining fatigue analysis and Simufact Welding based results showing welding residual stress, the cracking issue could be reproduced successfully.
Many customers, including leading automotive OEMS like Audi, Volkswagen, Daimler, Honda, Tesla, and others, Tier-1 suppliers like ZF, Bosch, Magna Cosma, Luk, Benteler, aerospace companies, general manufacturing companies like Siemens and Shanghai Electric, as well as a large number of universities worldwide are employing Simufact welding simulation technology for productive use or R&D purposes.
Users of Simufact Welding for structural welding simulation are, among others:
Your request will be forwarded to our Global Sales & Support Network that provides best-in-class industry-related application-specific sales and technical services - backed up by qualified local Simufact and Channel Partner experts.
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