Welding and Heat Treatment. December

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1 Welding and Heat Treatment Copyright ESI Copyright Group, ESI All Group, rights reserved All rights reserved. December

2 SYSWELD general introduction With this latest release, ESI has enhanced the welding & heat treatment simulation capabilities of SYSWELD 2017 to secure process feasibility and security, to control material characteristics and residual stresses, to keep distortion within specified tolerances, and to improve the performance of the product. The release includes new specific meshing capabilities to strongly reduce the time needed to create dedicated meshes for weld and heat treatment. To better support multi-pass welding, SYSWELD 2017 provides automatic control of the interpass temperature between each weld, ensuring better component integrity with a direct control of phase proportion and stresses. The new version also supports new manufacturing processes, including spot welding using spacers, friction stir welding and carbonitriding. New functionality allows the smart transfer of dedicated data from one simulation discipline to another, so that complete manufacturing processes can be simulated and used as input for performance. Furthermore, users of SYSWELD benefit from new core technologies to support the treatment of very large models, and to minimize the output file size. 2

3 ESI SYSWELD Welding Simulation Solution Single Pass Arc Welding Friction Stir Welding Physics Post Weld Heat Treatment Multi Pass Arc Welding Spot Welding Weld Grain Modeling Laser Welding Electron Beam Welding 3

4 ESI SYSWELD Heat Treatment Simulation Solution Quenching Nitro Carburizing Induction Hardening Forge-HT Chaining Solution Cast-HT Chaining Solution Weld-HT Chaining Solution Stamp-HT Chaining Solution Carburizing Nitriding HT Machining Chaining Solution 4

5 ESI SYSWELD Welded Assembly Simulation Solution Stamp Weld Assembly Chaining Solution for Distortion Control Weld Sequence Optimization Stamp Weld Assembly Durability Chaining Solution for Fatigue Performance Improvement Fatigue Analysis Stamping Welding Seam & Spot Weld Rupture Chaining Solution for Crash Performance Improvement Spot Welding Hardness Spot Shear Test Crash Analysis 5

6 Complete welding & Heat Treatment solution Mesh Material db Processes Analysis 6

7 Heat treatment December Copyright ESI Copyright Group, ESI All Group, rights reserved All rights reserved.

8 The Heat Treatment processes And the physics Through Hardening Quenched Hardening Carburizing Nitriding Carbonitriding Induction hardening 31

9 Complete solution from material management, mesh, process set up and analyses Material Management CAD Handling CAD 2 MESH Heat Treatment Engineering Analyses Optimization Material Data Manager Visual Mesh Visual Heat Treatment Visual Viewer 32

10 Visual Heat Treatment Dedicated platform to guide the end user Visual Heat Treatment, the complete workflow is represented as different steps and you are efficiently guided to complete the set up with minimum input Project Description Global Parameter Component Properties Heat Treatment Process Clamping Condition Loads and Deformations Solution Parameter 33

11 Strong Thermal Mechanical Coupling For large model management The main purpose of virtual simulation is to predict accurately the behavior of the product either qualitatively or quantitatively, as closer as possible to the reality. Coupling of thermo-metallurgical and mechanical computations brings the prediction of simulation closer to the real world scenario. This new feature is of great help in storing only important cards as the computation is in process loop and as we do not need to store all thermal out put to do the mechanical computation. It allows you to treat very large model without dealing with Gb of out put files. 34

12 User Defined Results Storage During Computation Where it can be defined in Visual? Industrial users are requested to build very large models with hundreds of thousands of elements and nodes, which lead to lengthy computation, thus it is very important to check and analyze key thermal and mechanical results during the computation without waiting for the end of the computation. With this new version, in order to reduce the results file size, you can choose the required results before to start the computation. From a dedicated dialog box, you can customize the output result file based on your need and optimize the output file size by keeping only relevant results on specific time 35

13 IT and CCT Diagram Automatic Calibration Accurate prediction of phase transformation based on automatic calibration In the database, a specific tool has been defined to allow automatic calibration of CCT and IT diagram. After calibration user can display and compare the computed diagram with the experimental one. Easy to use it allow accurate simulation of phase transformation 36

14 Carbonitriding Available in Visual Heat Treatment Carbonitriding is similar to gas carburization with the addition of ammonia to the carburizing atmosphere, which provides a source of nitrogen. Nitrogen is absorbed at the surface and diffuses into the workpiece Carbonitriding tends to be more economical than carburizing, and also reduces distortion during quenching. The lower temperature allows oil quenching, or even gas quenching with a protective atmosphere.kpiece along with carbon. 37

15 Heat Exchange coefficient 38

16 Time dependency for diffusion coefficient In some processes the decarburization is not so important and to well control it, it is then needed to define the diffusion coefficient based on time dependency. In the new version a new button named Coefficient Curve has been added. By selecting it, the classic Visual Plot Editor dialog box is opened and the user can define the diffusion coefficient based on time during the phase of enrichment and diffusion. 39

17 Heat Treatment simulation restart 40

18 Low pressure carburizing This process can be simulated with the current version of visual Heat treatment. Several cycles can be imported directly using Visual Plot Editor in.csv format. Accordingly the evolution of the carbon profile will be computed. Carbon Activity Carbon Content 41

19 Incremental Clamp Release Rigid clamps are released gradually When there are number of rigid clamps for a flimsy model in welding simulation, abrupt release of rigid clamps will have an impact on convergence of the simulation. Therefore it is important to simulate the real time scenario where the rigid clamps are removed gradually in sequence as the welding process is completed. To support this condition Incremental Clamp Release feature has been implemented. The release duration of the clamp that is released can be given by the user. This option is currently available only in Welding Advisor

20 Nitruration December Copyright ESI Copyright Group, ESI All Group, rights reserved All rights reserved.

21 Précipitation des nitrures de chrome ( CrN) Appauvrissement de la couche nitrurée en carbures de chrome Cr7C3 44

22 Activité des éléments chimiques N, C, Cr (%) Cr N C 45

23 Evolution de la fraction du précipité CrN (%) en fct du Temps 46

24 Evolution de la fraction du précipité Cr7C3 (%) en fct du Temps 47

25 Capability & Availability Weld Quality, Heat Treatment, Assembly /Welding 48

26 Thank You 49