DynaWeld's Applications

Transcription

1 DynaWeld GmbH & Co. KG Süd: Herdweg 13, D Wössingen Nord: Hermann-Löns-Straße 3A, D Brietlingen Kamen: Herbert-Wehner-Straße 2, D Kamen E-Post: Web: DynaWeld's Applications Welding Heat Treatment Hotforming Assembly and Manufacturing Feasibility and Benefits of Simulation

2 Software Products DynaWeld Preprocessor and environment for advanced welding and heat treatment simulations within forming steps or service load. Requires FEM-code LS-DYNA. MatPlusHQ Fast and easy to use simulation tool for heat treatment. Thermal analysis. LS-DYNA Finite element code with different solvers (Electro-magnetic, thermal, mechanic, fluid, chemistry) and methods (FEM, BEM, ALE, EFG, SPH) SimWeld Fast and easy to use simulation tool for welding process simulation for gas metal arc welding (GMAW) WeldWare Welding advisory tool. Data base with CCT-data and mechanical properties for general steels. Analytical aproaches for simple thermal analysis (cooling rate, preheating estimation) Auxilary tools for welders. JMatPro Software for material simulation. Prediction of material properties. 2

3 Benefits Prematurely detection of possible manufacturing problems causal research testing alternatives all before finalize the production facilities Virtual design of process, manufacturing and state of assembly in early stage without physical experiments and trials enables straight forward engineering save resources save cost Optimisation of process by simulation saves time saves cost increase productiveness Process chain simulation enables desing from material up to final product Simulation accompanied manufacturing monitoring the state of workpart guarantees high level of quality 3

4 What can't be simulated 4

5 Aplications and limitations Applications Distortion Strenght analysis Ultimate load analyis Forming, crash, coating Process chain analysis of many manufacturing steps Heat treatment, welding, forming, cutting, grinding Simplifying methods enables calculation for larger assemblys Simplyfieng methods reduce result quality Coupling of physics and detailing of models Melt pool evolution Weld nugget size Window of acceptable process parameter e.g. all welds of a ship Simulation time, capacity of computer Simulation methods State of assembly as initial state for further analysises Analysis and evaluation of temperature field Process, process parameter Microstructure Stress, strain, strain hardening Size of Simulation model Heat engineering Optimization, compensation Mechanical and metalurgical properties Limitations The more complex the model the nearer the limit Thermal model Mechanical model Electro-magnectical model Material model Fluid model Solidification kinetic Optical effects Cost Specialised staff 5

6 HotFormOpt Optimisation of hot forming process for pipe elbows Benefits Reality Simulation Increase of productiveness up to 300 % Reduce use of energy before optimisation after optimisation Förderkennzeichen: EFRE (Metatech) 6

7 HotFormOpt Optimisation of hot forming process for pipe elbows Benefits Increase of productiveness up to 300 % Reduce use of energy Förderkennzeichen: EFRE (Metatech) 7

8 Distortion Engineering Automotive Simulation task: prediction of deformation design of clamps, predeformation design of distortion compenstation Simulation benefit: safe of time to production safe of loops for tool optimisation safe of cost 8

9 Distortion Engineering Automotive 9

10 Distortion Engineering Railway and trains 10

11 Distortion Engineering Railway and trains 11

12 Assembly Simulation of multiple process steps 12

13 Multi stage simulations Stage 1 Temperature and deformation at end of first stage first weld Welding Stage 2 additional plate second weld bottom weld top weld Stage 3 tension test initial state stage 2 13

14 Multi stage simulations Stage 1 Stage 2 Stage 3 - Tension test Stage 2 upside down 14

15 Free Motion Filler Technology and other important issues for distortion engineering Tack welding Clamps and clamp closing distortion by clamp closing Predeformation distortion compensation Grinding and cutting distortion by residual stress release 15

16 Free Motion Filler Technology and other important issues for distortion engineering 16

17 Buckling effects special performance feature on LS-DYNA's shells Laser process low energy per length Laser process high energy per length Buckling effects during welding and during cooling 17

18 Buckling effects special performance feature on LS-DYNA's shells Laser process low energy per length Distortion scaled 5 times Laser process high energy per length Distortion not scaled 18

19 Multiple stage simulation keep history of prior proces e.g. process chain welding - forming Material change due to welding Material history kept in next simulation step (e.g. forming) Impact of different yield high yield in weld seam due to martensite low yield in base material Microstructure (Martensite proportion) Residual stress (v. Mises Stress) Thickness (Sheet thinning) 19

20 Welding Test Analysis of service behaviour Step 1: Laser welding - overlapp weld Step 2: Tensile test Results after Welding plastic strain Equivalent stress Hardness Yield Martensite proportion Longitudinal stress 20

21 Welding Test Analysis of service behaviour Evaluation of load service Elastic stress evaluation level Criterion to visualize the use of elastic capacity in different regions in the material 1 (red) no elastic reserve, yield point is reached. Elastic stress evaluation level as welded test plastic strain test Elastic stress evaluation level T-joint with filled weld 21

22 Welding Test Analysis of service behaviour Liquid material Elastic stress utilisation level Eqivalent stress Temperature 22

23 Resistance spot welding electrical thermal mechanical coupled 23

24 Multi-Pass Welding Weld of a pipe with 40 mm wall thickness Alloy Layer - GMAW 93 Layer - TIG 24

25 Multi-Pass Welding GMAW Weld of a pipe with 40 mm wall thickness Alloy

26 Disimilar Welds different materials in component and filler Dissimilar material properties - here dissimilar heat conduction - leads to nonsymetric heat transfer On mechanical part different thermal strains and mechanical properties influence the distortion behaviour and residual stress evolution. 26

27 T-Joint of thick plates with multi-layered filled weld Temperature and distortion 24 mm y-displacement Temperature 80 mm x-displacement x 27

28 T-Joint of thick plates with multi-layered filled weld Residual stress and strain Equivalent stress v. Mises Plastic strain Yield stress 28

29 T-Joint of thick plates with multi-layered filled weld Microstructure and Hardness Hardness Bainite Tempered bainite 29

30 T-Joint of thick plates with multi-layered filled weld Animation Temperature Plastic strain 30

31 T-Joint of thick plates with multi-layered filled weld Animation Tempered bainite Bainite Austenite 31

32 Heating of optical components laseroptic focus shift SmartScan Simulation of temperature field and heating due to laser load of optic elements. Das Projekt wird gefördert von der AIF Projekt GmbH, ZIM - Kooperationsprojekte, Tschalkowskistrape 49, D Berlin im Rahmen des Förderprogramms Zentrales Innovationsprogramm Mittelstand ' des Bundesministeriums für Wirtschaft und Energie (BMWi) - Fördermodul FuE-Kooperationsprojekte Förderkennzeichen VP NT4 Experimental measurement validated by simulation: 32

33 Heating of optical components due to laser for welding Welding of a car door 1st weld sequence Welding of a car door 10th st weld sequence 33

34 Implementation of material simulation Preheating - Welding - Heating - Quenching - Tempering Example Gear - Axle Process steps: 1) 0 s 60 s: 2) 61 s 63 s: 3) 63 s 5000 s: 4) 5000 s s: 5) 7000 s s: 6) 7500 s s: 7) s s: 8) s s: (1,2,3) Preheating Welding Cooling at air Heating - austinitsation Quenching in Oil with diving simulation Cooling at air Heating - tempering Cooling at air Simulation of material data with JMatPro (4) (5) (7) (6) (8) Steel C 0,11 Mn 0,45 Cr 1,52 Ni 3,30 10CrMoV 0,11 0,50 10,2 0,55 34

35 Benefit of Simulation Chain Result influenced by chemical composition of material Steel Equivalent stress 10CrMoV Steel Yield 10CrMoV with tempering Benefit: Steel Displacement 10CrMoV Calculate the final state of assembly modify the results by modification of material's alloy and use the results for design and optimisation. 35

36 Implementation of material simulation Preheating - Welding - Heating - Quenching - Tempering Example Gear - Axle Temperature Elastic stress utilisation level Eqivalent stress Austenit Proportion 36

37 MatplusHQ Simple fast and easy thermal heat treatment simulation Input: few parameters and geometry from CAD automatic FEM calculation Output: visible after a few seconds computing time heating of the complex component options to optimize the process 37

38 MatplusHQ results Simple fast and easy thermal heat treatment simulation results as easily interpretable graphics 38

39 Engineering of Heat Desingn of preheating on thick plates Thin compnent: Sheet thickness 6 mm Thick component: Plate thickness 100 mm Thick component: Plate thickness 100 mm Preheating temperature 320 C 39

40 Temperature Evolution in Molten Zone thin thick thick and preheated 320 C t8,5-5-time: 3,3 s t8,5-5-time: 13,8 s 40

41 Design of Microstructure by Cooling Time Martensite 30 % Martensit Ferrite / Perlite WeldWare t8,5-5-time: 13,8 s t8,5-5-time: 3,3 s Bainite 41

42 Welding Process Simulation with SimWeld Gas Metal Arc Welding Benefits: Results without welding experiment Design of process parameter Detailed results for other Evaluations Results: Melt pool geometry Droplet and wire temperature Energy, heat input, currency, voltage Temperature near weld Equivalent heat source for welding structure analysis 42

43 Prediction of weld quality Microstructure and mechanical properties Material Specification Chemical Composition WeldWare Weld-Pool HAZ Microstructure Yield Strength Ultimate Strength Hardness Ultimate Elongation WPS Welding Procedure Specification SimWeld S690 S355 Martensite t8,5-5-time of view-point high energy per unit length ultimate stress Martensite t8,5-5-time of view-point high energy per unit length yield stress 43

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