fenet barcelona feb2003 dle tejc
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SYSWELDSYSWELDComplete Finite Element
Solution for Simulation ofWelding Processes
Josef Tejc
MECAS ESI s.r.o. , CZ
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ESI Group
Company introductionCompany introduction
Uslavska 10 , Pilsen
Czech Republic
e-mail: [email protected]
web-page: http://www.mecasesi.cz
mailto:[email protected]://www.mecasesi.cz/http://www.mecasesi.cz/mailto:[email protected] -
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ESI Group
ESI Groups Virtual Try-Out SpaceESI Groups Virtual Try-Out Space
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SYSWELD2003
SYSWELD2003
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SYSWELD backgroundSYSWELD background
SYSWELD is a part of the SYSWORLD
Finite Element program family:
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SYSWELD backgroundSYSWELD background
SYSTUS is a general purpose Finite Elementproduct that provides most of the computation
capabilities that can be handled with implicit
Finite Element technology. Developed through
the last 4 decades and born in the Nuclear
Industry, it provides excellent non-linearcomputation capabilities.
Most of the features developed for SYSTUS are
shared through the SYSWORLD product family,i.e. it is possible to use them in SYSWELD too.
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General capabilitiesGeneral capabilities
SYSWELD 2003 simulates all physical
effects that are related to:
Welding and Heat treatment
Courtesy GM
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Architecture of the codeArchitecture of the code
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Coupled thermo-metallurgical analysisCoupled thermo-metallurgical analysis
Modified heat convection equation:
( ) QATLTPt
TCP
ji ijiji iii ii
=+
CCT diagram
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Real CCT diagramReal CCT diagram
T [C]
t [s]
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Models for phase transformationsModels for phase transformations
Leblonds model
for diffusion controlled transformation
Koistinen-Marburger law
for Martensitic transformation
( )
( )T
PTPTf
dt
dP eq
= .
.
rateolingheating/co...
etemperatur...
time...
mequilibriuphaseatproportion...
proportionphase...
T
T
t
P
P
eq
&
( )T)b(MsP(T) = exp1
etemperaturstart-Martensite...
tcoefficienlaw...
proportionphase...
Ms
b
P
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Model of the CCT diagramModel of the CCT diagram
T [C]
t [s]
Ferrite
Bainite
Martensite
M t i l ti
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Material propertiesMaterial properties
Mechanical properties: Youngs modulus
Poissons ratio
Thermal strain
Yield stress
Strain hardening
Usually, mechanical properties aredefined as a function of temperature and
phase proportions
Yi ldYi ld t
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Yield stressYield stress
Austenite
Martensite
Ferrite
Bainite
T [C]
Y [MPa]
M d l f h tM d l f h t
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Model of heat sourceModel of heat source
Double-ellipsoid
heat sourceHeat transfer into the
structure (t=20 s)
Cl i ditiCl i diti
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Clamping conditionsClamping conditions
Symmetryconditions
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Computed Thermo-
metallurgical Results
T t fi ld t t 20T t fi ld t t 20
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Temperature field at t=20sTemperature field at t=20s
Temperat re e ol tion (mo ie)Temperature evolution (movie)
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Temperature evolution (movie)Temperature evolution (movie)
Austenite evolution (movie)Austenite evolution (movie)
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Austenite evolution (movie)Austenite evolution (movie)
Bainite evolution (movie)Bainite evolution (movie)
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Bainite evolution (movie)Bainite evolution (movie)
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Computed Mechanical
Results
Evolution of displacements (movie)Evolution of displacements (movie)
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Evolution of displacements (movie)Evolution of displacements (movie)
Displacements UZ (with phase transf )Displacements UZ (with phase transf )
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Displacements UZ (with phase transf.)Displacements UZ (with phase transf.)
-0.5mm
-1.1mm
Angular distortion
z
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Stress (with phase transf )Stress (with phase transf )
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Stress yy (with phase transf.)Stress yy (with phase transf.)
Reduced tensile stress
level due to phase
transformations
y
Stress (without phase transf )Stress (without phase transf )
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Stress yy (without phase transf.)Stress yy (without phase transf.)
y
Stress (with phase transf )Stress (with phase transf )
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Stress xx (with phase transf.)Stress xx (with phase transf.)
x
Stress (without phase transf )Stress (without phase transf )
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Stress xx (without phase transf.)Stress xx (without phase transf.)
x
SummarySummary
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SummarySummary
The difference in computed distortions with
and without phase transformations is about
30% The difference in computed stresses with
and without material transformations is
remarkable
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Example of anIndustrial Application
Example of anIndustrial Application
Simulation of Welding of a
T-joint Made from AlMgSi
Courtesy ofCourtesy of
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Courtesy ofy
Process movie (accelerated display)Process movie (accelerated display)
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Process movie (accelerated display)( p y)
Description of the taskDescription of the task
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pp
A rectangular hollow profile is welded with 4
joints on a thin-walled plate
The computation of distortions during andafter welding is extremely sensitive due to
general instability of the arrangement
The edges of the plate are free
The plate is thin-walled and has a low resistance
against bending
The welding joints influence each other
To a certain extent, this is the worst case for
simulation engineering
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Displacement UZ after weld 1 (t=5.2s)Displacement UZ after weld 1 (t=5.2s)
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( )
Positive buckle atthe edge parallel
to WELD 1
Z
Displacement UZ after weld 2 (t=11.3s)Displacement UZ after weld 2 (t=11.3s)
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Positive buckles at
the edges parallel toWELD1 and WELD2
Z
Displacement UZ after weld 3 (t=17.4s)Displacement UZ after weld 3 (t=17.4s)
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Positive buckles at
the edges parallel
to WELD1,
WELD2 and
WELD3
Z
Displacements UZ after weld 4 (t= 22.10s)Displacements UZ after weld 4 (t= 22.10s)
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Still a positive buckle at
the edge parallel to
WELD1.
However, the
contraction of WELD4
decreases the positive
buckle of WELD1 andWELD2.
Z
Cooling from 22 to 1000 s (movie)Cooling from 22 to 1000 s (movie)
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g ( )g ( )
Cooling from 22 to 1000 s (movie)Different scaling!
Cooling from 22 to 1000 s (movie)Different scaling!
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Process movie - evolution of distortions at theedge parallel to WELD 2
Process movie - evolution of distortions at theedge parallel to WELD 2
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Interpretation of resultsInterpretation of results
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The computed evolution of the distortions of the
edge parallel to WELD2 is nearly coincident
with the displacements shown in the processmovie
The final displacements have been measured
to around 6mm
The final displacements computed are around
6mm
The computed displacements correlate wellwith the experiment
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Some of the NewFeatures of
SYSWELD 2003
Some of the NewFeatures of
SYSWELD 2003
Interfaces PAM-STAMP/SYSWELDInterfaces PAM-STAMP/SYSWELD
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In SYSWELD 2003, it is possible to readand write PAM-STAMP mapping files, in
order to: Import results from a stamping simulation in
a welding simulation
Import results from a welding simulation in a
stamping simulation
A typical application is the stamping of weldedtailored blanks
Door panel - real imagesDoor panel - real images
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fehlerfrei umgeformtes Bauteil
Courtesy of AUDI
Interfaces PAM-STAMP/SYSWELDInterfaces PAM-STAMP/SYSWELD
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Plastic strains:
Min/Max : 0/0.587
Courtesy of AUDI
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Welding Assembly simulationWelding Assembly simulation
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Material databaseMaterial database
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For Welding, the following materials are available
AlMgSi
Typical automotive aluminium alloy
S355J2G3 (1.0570, St 52-3, Fe 510 D1, Fe 510 D1 FF,CSN 11 523)
Typical ship building steel
X20CrNi13 (1.4201, Z20C13, AISI 420, CSN 17 022)
Stainless steel
X5CrNi 18 10 (1.4301, Z7CN18-09, AISI 304,
CSN 17 240)
Stainless steel DC04 (St 14, St 4, AISI 1008, CSN 11 325)
Typical car body / stamping steel, deep drawing quality
ESI Groups solution of present daysESI Groups solution of present days
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SYSWELD:
Complete solution for realistic
simulation of welding processes
Process
Product
COMPARISON WITHEXPERIMENTS:
In cooperation with industrial partners
a number of experimental projectswas done to proof tight agreement
between results of simulation and
reality.
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