FENET Barcelona Feb2003 DLE Tejc

8/10/2019 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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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



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Positive buckles at

the edges parallel toWELD1 and WELD2

Z



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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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FENET Barcelona Feb2003 DLE Tejc