Manufacturingsimulation in the shipbuilding area Simufact Eng. GmbH Schafstall, H.
Simufact Engineering stands for Simulating Manufacturing More than 20 years of professional experience Over 50 high skilled experts in Germany Powerful team worldwide Business Unit of MSC Software Manufacturing Division
What are we doing? Design is ok Fatigue is proofed NVA is ok CAD-data is created but.. How can I manufacture it? Without any defects? For a low price? With existing equipment? What is the out coming geometry? What are the final properties? How can I assembly it? (weld) Die life of my tools?
Prozesssimulation
Fields of Applications Casting Metal Forming Sheet Metal Forming Bulk Metal Forming Machining Joining Welding Coating Mechanical Joining Changing Material Properties *) *) e. g. heat treatment: hardening, carburization etc.
Fields of Applications Casting Sheet Metal Forming Metal Forming Machining Bulk Metal Forming Joining Welding Coating Mechanical Joining Changing Material Properties *) *) e. g. heat treatment: hardening, carburization etc.
Simufact s Applications Process Chain Automotive Joining Automotive supplier Sheet Metal Forming mechanical joining welding Bulk Metal Forming 1995 2000 2005 2008 2010 2014
Simufact s Applications Application oriented
Simufact s Applications METAL FORMING All applications, independent from temperature, material, machine, and its kinematics Hot Forging Open Die Forging Cold Forming Ring Rolling Sheet Metal Forming Rolling Mechanical Joining Heat Treatment
Simufact s Applications METAL FORMING WELDING Distortion analysis Different heat sources Fixing strategies Multiple robot support Spotwelding
Simufact Environment Who? What? Why? 1 1 1 2 2 2 Manufacturing process strategy Optimized process parameters Material characteristics Complete process chains Cost reduction for process/ tool design > 50% Reduce overall cost of production by robust serial processes > 30% Improve product quality > 20%
Business Objective Source: Prof. Klaus Ehrlenspiel et. al. TU München Institute of Product Development 100% influencing costs Cost situation in Manufacturing Industry 5% 7% 22% 75% 18% 50% 25% 70% 28% 38% Business Objective accruing costs Approx. 2/3 9% 3% Development Production Planning Production Material & Supplier Sales
Common Strategy Combining the world of product design, part manufacturing and assembly Properties of material and structures are changing due to treatment and manufacturing Manufacturing: Robust serial production Efficient, free of faults, cost optimized Meeting the specs of the final part Product Design/ Product Performance: Design properties Product specification Traditional CAE
Incremental forming
incrementel forming Open die Forging Radial Forging Shell forging Rotational partial forging Ringrolling
From casting to open die forging Chemical composition and distribution 17
Open die forging + grain size distributation
Open die forging
Heat treatment Phase Distribution during forming and after HT Bainite Ferrite 20
Ring Rolling Automatic process control 21
Ring Rolling Automatic process control 22
Laser and Arc Welding
Background Motivation Simufact.welding was completely driven by the German automotive industry following their requirements and specification Objective new innovative and user-friendly tool for welding simulation close to real manufacturing open concept supporting best solver technology useable for R&D and shop-floor (production departments)
Aspects of welding analysis Welding simulation Process simulation Structural simulation Material property simulation Process Structural Material Simufact.welding Bildquelle: Radaj 2002 Specific solutions for assembly processes
Why Welding Simulation? High temperature gradients lead to: Distortion Residual stresses Changes in microstructure Temperature Distortion Residual stresses with effects on: Dimensional accuracy Surface quality Behavior during painting Strength Crash Fatigue behavior Several measures: Geometry Welding order Clamping and tack strategy Seam length and position other...
Effect of heat
Audi Example Computational time in hours Laser welding of a door joints 7 parts 74 laser weldseams 500.000 Elements radial domain decomposition decoupled method Fixing Weldpath 750.000 nodes # Domains 2 heat sources per seam Experiment vs. Simulation
Audi Example Weld seams Study of welding strategy Strong distortion reference = 100% continuous seam high stiffness stich seam less heat weak stiffness different welding sequences optimized strategy 70% 30% improvement offset stich seam less heat medium stiffness
Welding Example Courtesy: Distortion of a MSG-welded part simulation experiment refinement fully automatically heat source optimization comparison simulation vs. experiment
Welding of a Chassis Suspension Clamping Concept
Welding of a Chassis Suspension Basic Model
Welding of a Chassis Suspension Modelling of Clamping Concept Clamping Bearing Fixing
Welding of a Chassis Suspension Time Table in the Process Control Center for Bearings, Fixings, Clampings and Robots (weldpasses, pause time)
Simufact welding model
Welding of a Chassis Suspension Calculation time 6 hours
Welding in shipbuilding Tandem welding Hybrid MIG/Laser
Tripel Bevel 50mm thickness plates with double-v and single-sided-v bevels
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Welding example with phase transformation Current flow stress for a multilayer welding example
Calculation of phase fraction cooling heating ferritic perlitic phase (base material) bcc austenitic phase fcc increasing cooling rate ferrite perlite bainite martensite
Multi phase model for forming, welding and marc (in 2016) Phase dependent material properties Building of austenite during heating up and phase changes during cooling phases are calculated based on TTT diagrams 4242
Best in class physical modelling thermal mechanical microstructural coupling Thermal Analysis Thermal stress Heat generation due to mechanical work Mechanical Analysis Real elastic plastic material modelling Multi-phase material model with phase transformation Material parameters for material dependent on material phase Microstructure Properties are calculated based on a mixture rule of the phases
Summary: Strong Points Welding Simulation: laser welding/ arc welding Ease of use model explorer process control center template technique optimized for users from production area Fast and flexible high speed parallelization thermal cycle technique decoupling methods Comprehensive physics powerful material models realistic, intuitive clamping and fixing Flexible balancing between performance and accuracy Highest level on results quality
Process Chain
Total Process Chain Process history from sheets (e. g. cold hardening) Sheet forming Cold forming Heat Treatment Joining Crash Process history from joining Simufact.forming Simufact.welding MSC.Marc
Example Crash box Use case: The crash box absorbs energy during an impact Different crash boxes: after impact: Source:http://diaspenefab1975.blog.co.uk/2013/12/09/crashbox-auto-17326136/
Example Crash box: Crash simulation Absorbed energy: Including history Geometry only
Summary For the sustainable development of the customers technological know-how in manufacturing areas We offer: This means: The benefit: Simufact.forming and Simufact.welding: modern state-of-the-art and reliable simulation tools Wide range of applications with full consideration of manufacturing process chains We enable our customers to solve typical technical issues by virtual process design to achieve higher safety in business planning and to stabilize their overall performance figures on a higher level Shift expensive physical try-outs into a modern, virtual manufacturing simulation tool. This will contribute to increase profitability and to enter new business opportunities within the shortest time.
Thank you very much for your attention どうもありがとうございました simufact engineering gmbh Tempowerkring 19 21079 Hamburg Germany info@simufact.de www.simufact.de