Simufact Welding
Simufact Welding is used for modelling and optimising a wide range of fusion and pressure welding processes, taking into account weld sequence and clamping. Processes such as arc welding, laser beam welding, electron beam welding, brazing, resistance spot welding as well as the generative manufacturing process ‘Direct Energy Deposition’ (DED or WAAM) can be modelled in Simufact Welding. Additionally, Simufact Welding can be used to model the heat treatment, different variants for cooling and unclamping as well as the mechanical load on welded structures.
How can Simufact Welding support you with the design of a welding process or an assembly?
Depending on the level of detail and data quality you are able to …
- Calculate local and global properties of a welded structure, i.e. global and local deformations, residual stresses and metallurgical phases
- Learn how changes in the assembly design (i.e. addition, movement or removal of stiffeners, changed fillet geometry) influences the final quality of the product
- Check the influence of clamping conditions, also learn if all clamps are necessary
- Investigate hot spots with respect to temperature or stresses that might lead to cracks or damage of the structure
Modular structure
Simufact Welding is a modular software, subdivided into application modules providing welding process-specific functionality and additional modules providing material data and parallelization technology boosting simulation performance.
Core functionality is provided by the Welding Hub and its associated Thermal Joining application modules, offering the possibility of pre- and postprocessing as well as calculation of thermal joining processes. Additionally, a Resistance Spot Welding module is available. An optional bundle with MSC Apex Modeler provides CAD and meshing capabilities.
Standard modules include the capability of:
- Flexible definition of equivalent heat sources for thermal joining
- Definition, visualization and editing of material data
- Possibility of parallelization
- Scaled simulation approaches
- Definition of time-temperature curves for heat treatment
Process chains and data exchange
The capability of transferring simulation results from one manufacturing step to subsequent steps is a prerequisite for result accuracy in the entire simulation process chain.
In combination with Simufact Forming it is possible to model entire process chains, for instance forming processes on components that are welded in the next step and vice versa.
Data exchange between Simufact Forming and Simufact Welding allows for stepwise calculations that are based on previous results. This approach makes it possible to calculate welded assemblies, or to carry out process chain simulations.
Therefore it is possible to integrate welding with pre- and post-processing in a common numerical framework. The easy data transfer allows consideration of the material history with respect to a previous forming process, as well as the fatigue response of a calculated weldment.
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We pride ourselves on empowering each client to overcome the challenges of their most demanding projects.
Enteknograte offers a Virtual Engineering approach with FEA tools such as MSC Softwrae(Simufact, Digimat, Nastran, MSC APEX, Actran Acoustic solver), ABAQUS, Ansys, and LS-Dyna, encompassing the accurate prediction of in-service loads, the performance evaluation, and the integrity assessment including the influence of manufacturing the components.
Resistance Spot Welding: Finite Element Simulation of RSW
Resistance Spot Welding is a pressure welding process during which the sheets are pressed together locally with the help of fitted copper electrode welding guns. The electrical current between the weld guns causes a heating and melting of the joining partners, creating a small circular welded area between them.The standard approach in a RSW model contains fully coupled electrical, thermal, metallurgical and mechanical steps, so the heat generation is calculated due to Joule’s heating coming from electrical current and resistivity between components.
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Arc welding processes (SMAW, GMAW [MIG], GTAW [TIG], SAW, …) are of the highest economic importance due to their flexible application and relatively low equipment costs for both robotic and/ or manually controlled joining. Due to a high melting rate and a high gap-bridging ability these processes are found most notably, in steel plants, power stations and shipbuilding.
Read more... Pressure Welding FEA Simulation: Friction welding, Resistance welding, Friction spot welding
Pressure welding is a group of diffrent joining processes which have all in common that the components are joined by applying heat and pressure. The heat can either be generated by an electrical current flow (resistance welding) or by friction (friction welding).
Read more... Finite Element Simulation of Brazing
Brazing is a thermal joining process which connects metal components with melted filler material. The filler usually has lower melting point compared to components. Main advantages of brazing lies in relatively low heat input and the capability to create a joint of considerable strength and durability.
Read more... Fatigue Analysis of Welded Structures
Enteknograte use advanced Numerical simulation software and methods to simulate the welding behavior in real service load condition and estimate its Durability and Fatigue Life with Ansys Ncode, Simulia FE-Safe, MSC CAEFatigue and FEMFAT. The Seam Weld and Spot Weld fatigue simulation enables the fatigue analysis of joints including different type of welding such as fillet, overlap, spot welds in thin sheets and laser welded joints.
Read more... Finite Element Simulation of Laser Beam / Electron Beam Welding
Laser Beam welding is a thermal joining process, in which a component is heated and welded by a laser beam. It is a high-end process for application cases requiring the highest degree of precision. A huge advantage of laser beam welding lies in the relatively narrow heat affected zone. Electron Beam welding is a thermal joining process, in which a component is heated and welded by electron beam.
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Structural vibration can be a source for many product related problems; it can cause fatigue and durability problems as well as adverse reactions to the user or bystanders in the form of undesirable vibrations that can be felt or heard. As well, undesired structural vibrations can prevent products from operating as required and potentially becoming a safety concern. The Vibration Fatigue simulation predict fatigue in the frequency domain and it is more realistic and efficient than time-domain analysis for many applications with random loading such as wind and wave loads.
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We analyze system-level thermal management of vehicle component, including underhood, underbody and brake systems, and design for heat shields, electronics cooling, HVAC, hybrid systems and human thermal comfort. Our Finite Element (LS-Dyna, Ansys, Abaqus) and CFD simulation (Siemens Start-ccm+, Ansys Fluent , Ansys CFX and OpenFoam) for heat transfer analysis, thermal management, and virtual test process can save time and money in the design and development process, while also improving the thermal comfort and overall quality of the final product.
Read more... Metal Forming Simulation
Sheet Metal Forming, Hot Forging, Cold Forming, Open Die Forging, Roll Forming, Extrusion and Heat Treatment with Ansys, Abaqus, LS-Dyna and Simufact
Using advanced Metal Forming Simulation methodology and FEA tools such as Ansys, Simufact Forming, Autoform, FTI Forming, Ls-dyna and Abaqus for any bulk material forming deformation, combining with experience and development have made Enteknograte the most reliable consultant partner for large material deformation simulation. Metal Forming Simulation include Springback Compensation, Surface Defects, Cost Estimation and Phase Transformation in Sheet Metal, Hot Forge, Rolling, Extrusion, Open Die Forging and Heat Treatment Finite Element Analysis.
Read more... Finite Element Simulation of Heat Treatment
In principle, there are two kinds of heat treatment processes: processes resulting in a thorough change of the microstructure and processes that result in merely changing regions close to the surface of the component. Examples of the former would be thermal processes, such as annealing and hardening. Examples of the latter, thermochemical processes, would be diffusion and coating processes, such as carburization, case hardening, nitrating, boriding.
Read more... Additive Manufacturing and 3D Printing
FEA Based Design and Optimization with Simufact, Abaqus, ANSYS and MSC Apex for powder bed fusion (PBF), directed energy deposition (DED) and binder jetting processes
With additive manufacturing, the design is not constrained by traditional manufacturing requirements and specific number of design parameters. Nonparametric optimization with new technologies such as Artificial Intelligence in coupled with Finite Element method, can be used to produce functional designs with the least amount of material. Additive manufacturing simulations are key in assessing a finished part’s quality. Here at Eneteknograte, dependent of the problem detail, we use advanced tools such as MSC Apex Generative Design, Simufact Additive, Digimat, Abaqus and Ansys.
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Machine learning is a method of data analysis that automates analytical model building. It is a branch of Artificial Intelligence based on the idea that systems can learn from data, identify patterns and make decisions with minimal human intervention. With Artificial Intelligence (AI) applications in CAE, that is Mechanical Engineering and FEA and CFD Simulations as design tools, our CAE engineers evaluate the possible changes (and limits) coming from Machine learning, whether Deep Learning (DL), or Support vector machine (SVM) or even Genetic algorithms to specify definitive influence in some optimization problems and the solution of complex systems.
Read more... Finite Element Simulation of Crash Test and Crashworthiness with LS-Dyna, Abaqus and PAM-CRASH
Crashworthiness focuses on occupant protection to reduce the number of fatal and serious injuries. This research is responsible for developing and upgrading test procedures for evaluating motor vehicle safety. Crashworthiness research encompasses new and improved vehicle design, safety countermeasures and equipment to enhance occupant safety.
Finite Element Analysis (FEA) has been the trend in virtual crash design over the last decade. The predictive capabilities of FEA allow engineers to fully understand a crash event in a virtual environment, thus limiting the number of physical tests that need to be executed and thus saving costs.
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AeroAcoustics, VibroAcoustics and NVH Analysis in Automotive, Aerospace, Shipbuilding and Consumer Product Manufacturers.
The need to reduce noise and vibration can arise because of government legislation, new lightweight constructions, use of lower cost materials, fatigue failure or increased competitive pressure. With deep knowledge in FEA, CFD and Acoustic simulation, advanced Acoustic solvers and numerical methods used by Enteknograte engineers to solve acoustics, vibro-acoustics, and aero-acoustics problems in automotive manufacturers and suppliers, aerospace companies, shipbuilding industries and consumer product manufacturers.
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