product presentation simufact.welding

est welded 

Welding structure simulation 

Simufact.welding 3.1

What is Simufact.welding? 

Simufact.welding 

Slide 2 

Virtual process design 

Temperature distribution in components and heat 

transfer into clampings 

Prediction of welding distortions and 

residual stress during welding and after 

releasing tools 

Simulation of local material properties 

(e.g. flow stresses or phase fractions) 

Graphical presentation and export 

of tracking points 

Simulation of process chain and 

further mechanical analysis 

Simufact.welding is directed to welding 

specialists in research, development and 

manufacturing. 

There is no need to be a specialist for 

computer aided calculation methods.

What can Simufact.welding offer? 

Virtual process design of welding processes including tacking, fixing concept and 

pre-heating 


Slide 3


Virtual process design of welding processes including tacking, fixing concept and 

pre-heating 


Slide 4


Temperature distribution in components and heat transfer into clamping tools 


Slide 5


Prediction of distortions during and after clamping and prediction of residual 

stresses due to welding 


Slide 6


Fast process variations by copy function 

For instance minimization of distortions via varying the clamping conditions 


Slide 7


Automatical real simulation of possible gap formation during welding by high 

resolution contact between components 


Slide 8 

F ? 

F ? 

Gap ? 

F ? 

F ?


Simulation of local material properties e.g. changed flow stresses of phase 

fractions 


Slide 9


Graphical presentation and export of tracking points 


Slide 10

How does Simufact.welding works? 


Slide 11 

Geometry and meshing 

Weld paths and fillermaterial 

Mechanical and thermal boundary 

conditions 

Heat source modeling 

Time management 

Prediction of local material properties 

Postprocessing

Geometry and meshing 

• Finite element meshes can be imported from a Nastran-bulk-file (*.bdf) 

• Automatic mesh refinement during welding for high thermal gradients 


Slide 12

Weldpath and fillermaterial 

• Easy definition of weld paths via node picking or by import of a csv-file 

with path coordinates 

• Automatic generation of a FE-mesh for filler material 


Slide 13

Mechanical boundary conditions 

• Automatic generation of clamping geometries 

• Adjustable clamping times 


Slide 14 

Contact between components 

and filler materials 

Contact between components and tools: 

Spring stiffness C: 

Automatic determination of the direction 

rectangular to the contact surface 

Initial force F: 

Automatic determination of the 

direction rectangular to the contact 

surface

Therma boundary conditions 

• Automatic detection of free surfaces for heat dissipation 

• Heat flux definition on contact surfaces 

• Variable initial temperature for preheated work pieces 

• Predefined default values 

Initial work-piece 

temperature 


Slide 15 

Convection: 

Q c = -h A (T 1 - T 2) 

Heat transfer via surface contact and 

heat transfer coeffient 

Q CHT = α A (T 1 - T 2) 

Emissions coeffizient ε: 

Stefan-Boltzmann-equation: 

Q E = -ε A (T 1 4 - T2 4 ) 

(0 ≤ ε ≤ 1)

Heat source models 

• Positioning and rotation of heat sources 

• Automatic projection on surface with offset function 


Slide 16

Heat source models 


Slide 17 

Combination of heat sources using offset function

Time management 


Slide 18

Material modeling during welding 

Simufact.welding includes simufact.premap modules (Nancy model) 

Interface to JMatPro etc. 


Slide 19 

austenite 

Austenite 

während during 

Schweißen 

welding 

Martensit 

nach 

Abkühlen 

martensite 

after cooling

Postprocessing 


Slide 20

Three-point bending tests 

Process chain welding – forming / acc. plastic strains as an indicator for damage 

Temperature distribution during welding 

Acc. plastic strains during welding 


Slide 21 

Acc. plastic strains during forming 

Highest level of 

accumulated 

plastic strains at 

the weld seam 

close to forming 

tools

Deep drawing and welding 

Residual stress after welding 

Without forming results With forming results 

Accumulated plastic strains after welding 


Slide 22 

Lifting distortion of the cover on 

the opposite edge 

Calculated without forming results 

Calculated with forming results 

• After welding the component is highly plastically deformed and under high residual 

stresses which influence the stress distribution and distortions during and after welding

Welding and deep drawing 


Slide 23 

Implementation of welding distortions into forming analysis 

Temperature distribution during welding 

Acc. plastic strains during welding 

Model: Forming of tailored blanks 

accumulated plastic strains after forming

Deep drawing and welding 

Implementation of plastic strains and residual stresses for into welding analysis 

• Forming simulation including unclamping, cooling, trimming and positioning for welding can be 

performed in simufact.forming 

• Import of formed geometry from arc-files 

• Import of forming results from arc-files via introducing a “pre state” block in the dat-file (in 

simufact.welding 3.1.0 by hand) 


Slide 24 

Right mouse click Import geometries

Calculation quality 

• Determination of residual stresses are said to be a quality proof for structural 

weld analysis 

• International Round Robin test (IIW) is used as a reference example (German 

standart DIN SPEC 32534-1: Numerical welding simulation — Execution and documentation) 

• 2-Layer TIG weld 

material 316LNSPH / 316L 

voltage 9 V 

current 155 A 

welding velocity 40,2 mm/min 


Slide 25 

distortion angle 

measurement: 0.033° 

simulation: 0.032°

Conclusion 

• Welding simulation can be user-friendly. Simufact.welding 

offers: 


Slide 26 

a.) an automatic mesh refinement 

b.) handles incompatible meshes 

c.) offers a fillet generator for FE-Meshes 

d.) a fast method to define weld paths and 

process orientation 

e.) heat source models and interfaces to 

process simulations 

f.) modeling of clamping tools 

• A fast virtual optimization of clamping conditions, tacking is 

possible 

• A coupling of simufact.welding and simufact.premap allows a 

prediction of the phase proportions during and after welding 

• A coupling of simufact.welding and simufact.forming allows 

process-chain modeling

simufact engineering gmbh 

Tempowerkring 3 

21079 Hamburg 

Tel.: 040-790 162-0 

Fax: 040-790 162-22 

office@simufact.de 

www.simufact.de

product presentation simufact.welding

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