efficient setup and documentation · - arc welding - gmaw, saw, tig - laser - electron beam -...
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Tobias LooseIngenieurbüro Tobias Loose, Herdweg 13, D- 75045 Wössingen,[email protected] www.tl-ing.eu
Efficient Setup and Documentation of Simulations for
Welding and Heat Treatment with DynaWeld
Simulationsforum Weimar08.11.16 till 10.11.16
Foto: ISF
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HeatingThermal HeatingInductive Heating
Quenching
Carburisation
Tempering
Quenching
Case Hardening
Inductive hardening
Press hardening
Heat treatment overview
Typeof heat treatment
Single process steps
Design of properties by local change of material properties and microstructure
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ClampingPredeformations
Cooling
Heating
ReheatingTempering
Weld Process Type- Arc Welding- GMAW, SAW, TIG- Laser- Electron Beam- GMAW-Laser-Hybrid- Resistive Welding, RSW
single or multi layered welds,
tack welds
Dimension10 µm .. 500 mm
Welding overviewwelding structure analysis
Type of Welding Single process steps
Distortion - Residual Stress - Material Properties after Welding
Grinding and Rewelding
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Substructuring of models for welding and heat treatment
SIMULATION
MODEL
GeometryMeshing or import
mesh from prior steps
Heat Source
Heating Carburization
MaterialData, and parameter
calibration
ProcessClamps and Boundarys
Quenching Media
Trajectories
FEMadditional settings:
load, contact, cinematics...
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Benefit of sub structuring
Complex simulation
task with many disciplines
Materialspecialist
Meshspecialist
FEMspecialisteasy to mange by task sharing
Weldingspecialist
Heat Treatmentspecialistoutsourcing single tasks
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Definition of simulation steps
SIMULATION
MODEL
POST
FILE OUTPUT
RESULT
REALITY
Mesher
Pre-Processsor
Solver Post-Processsor
DynaWeld LS-DYNA LS-Pre-Post
DynaWeld repesents a simulation environment with special preprocessors
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DynaWeldenvironment and preprocessor
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DynaWeldenvironment and preprocessor
DynaWeld is not an Island-Solution!
Customer definedEnvironment:
•Mesher•PreProcessor•PostProcessor•Auxilary Software
Process Chain
Linux and WindowsExcel and Libre Calc
Plug In for existing Software environmentas well as stand alone
Heat Treatment and Welding
relatedauxilary Tools
Interface•Material Simulation•Welding Process Simulation
User defined Keyword→ no limitation in modeling
Supports LS-DYNA FE-Code one Code - many Solvers - one License Fee
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MaterialFoto: Edyta Łopatecka
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Phase transformation during coolingCCT-diagram
Quelle: Bernd Hochholdinger, DYNAmore Swiss
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Phase kinetic models
Law:Koinstinen-Marburger
Parameter:Tstart: Start Temperature MSa: kinetic faktor KM
Use:f(temperature)diffusionless transformation
Austenit → Martensit
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Phase kinetic models
Law:generalized JMAK
Jonhson-Mehl-Avrami-Kolmogorov
Parameter:xeq: Proprotion at equilibrium (T) PEQn: form parameter (T) Nt: kinetic faktor (T) TAUf,f': Leblond factor (dT/dt) F, F'
Use:f(temperature, temperture gradient, time)diffusion-driven transformation
Austinitisation, TemperingAustenite → Ferite, Perlite, Bainitephase transformation Aluminium
Advantage:no limitation on material type nor chemical composition. Fitting according:temperatur(T) and temperature rate(dT/dt)
Disadvantage:needs calibration on existing CCT or TT
based on Avrami equitationextended by Leblond
,
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Materials with phase kinetic models in LS-DYNA
*MAT_254 / *MAT_GENERALIZED_PHASE_CHANGE
Heat treatmentWelding all materials
Laws:Koinstinen MarburgerOddyKirkaldygeneralized JMAKTime criteriumlist might be extended
userdefined assignment of laws
Features:24 PhasesShells, Solids, 2D-shellsWelding featuresPhase transformation strainTransformation induced plasticity (TRIP)Subcycling for phase transformationTemperingHardeness computation
Simulation of PROCESS-CHAIN feasible
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Selected features: DTEMP
Phase transformation calculation temperature requires limit on tempearature stepPhase transformation shall not reduce time step of mechanical solverDTEMP = maximum allowed temperature step drives subcycle for phase transformation:
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*MAT_254 calibration of phase transformation law
given CCT Data
LS-DYNA calculation
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Selected features: phase transformation strain
If Phase A and B have different densityin case of phase transformationadditional strain arises due to volume change:Phase Transformation Strain.
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Simplified approach for single phase model *MAT_270
Heating
Cooling
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Validation Nitschke-Pagel test
Distortion w:Experiment: 0,34 mmSysweld: 0,32 mmLS-DYNA: 0,34 mm
Loose, T.: Einfluß des transienten Schweißvorganges auf Verzug, Eigenspannungen und Stabiltiätsverhalten axial gedrückter Kreiszylinderschalenaus Stahl, Diss, Karlsruhe, 2008
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DynaWeld – Management forhigh sofisticated welding and heat treatment materials
Material DynaWeld Material User defined
Import and extensions:Base material phaseLiquid material phaseTempering phaseFlowcurve adjustmentWelding settings
JMatPro
WeldWare
other material simulation software
LS-DYNAMaterial keyword-file
multi phase *MAT_254
LS-DYNAMaterial keyword-filesingel phase *MAT_270
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DynaWeld Material - Import
Interfaces
Settings and Extensions
single phase multi phase
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DynaWeld Material – Documentationspreadsheet DynaWeld-Material-Check
Graph for each material parameter
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DynaWeldHeat Treatment
Foto: Edyta Łopatecka
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DynaWeld – Management for high sofisticated heat treatment simulation setup
Model Setup DynaWeldHeat TreatmentOven curve
HT-ProcessHT-ParameterHT-Solver Settings
Carburization
Quenching media
Diving
LS-DYNA Keyword-files
Dokumentationin spreadsheed format
LS-DYNA solver run
LS-DYNAMesh keyword-file
LS-DYNAMaterial keyword-file
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DynaWeld Heat Treatment - Process
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DynaWeld Heat Treatment - Parameter
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Foto: Edyta Łopatecka
DynaWeldWelding
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Laser welded sheet with tensile test
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DynaWeld – Management for high sofisticated welding simulation setup
Model Setup DynaWeldWelding Trajectory
ProcessTimestep adjustmentBoundary and ClampsParts, Material assignmentContactSolver Settings
Heat Source
Clamp Kinetic
LS-DYNA Keyword-files
Dokumentationin spreadsheed format
LS-DYNA solver run
LS-DYNAMesh keyword-file
LS-DYNAMaterial keyword-file
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DynaWeld Process
Types of heat sourcesurface heat sourcevolumetric heat sourcepart heating
Geometric shapeselipsoid – double elipsoidcylinderconus – double conus
Heat input onshell, shell 2Dsolidsegment
Start, end, intermediate time
Multi robots simultaneous
Multiple heat source
Reverse option
Reorder of sequence
Multi layered weldsauto deactivation of not yet deposit material
SimWeld interface
supports the newLS-DYNA heat source- on shells and solids- shell thickness distribution- engergy input control- sub cycling- mesh independent- time step independent
auto fill or copy option
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Weldpath definition - trajectory and reference
Trajek
tory No
deSet
Refere
nce No
deSet
Rotation of reference
Global coordinate system
Local coordinate systemheat source
uv
ww-offset
v-offset
u: Trajektory directionv: Torch directionw: Lateral direction
xz
y
Definition with one Nodesetauto detection of reference
normal on surface*BOUNDARY_THERMAL_WELD_TRAJECTORY
Local adjustment:- rotation- v-offset reference direction- w-offset lateral
automatic calculation of thelength of trajectory
Display of trajectory,reference, startpoint
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DynaWeld Boundary
time
forcedisp
Clamping
Clampedforce driven or
displacement driven
Unclamping
Single point constraints (SPC)
Symetry surfaces
Force on Nodes or Node Sets
Displacement on Nodes or Node Sets
Force or Displacement:•user defined ramp at start and end•local coordinate system•Predeformation•Prestress
Force or displacement driven clamps
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DynaWeld Contact
Welding contactchange friction → tied by temperature
Friction contact
Tied contact
Shell edge to surface or solidfriction or tied contact
Node to surfaceauto-correct of large penetration
mechanical only
Special featuressmooth option for curved sheets
mortar option for implicit analysisshell thickness considered automatically
mechanical and thermal
mechanical
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DynaWeld-Welding Input file generator
Analysis Options
Generate Input•one file•structured input•single task creation
Clean Work Directory
Check options
Run and Kill
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DynaWeld Tools
Create Variants
Heat iput check
Automatisation for results along path
or time history at nodes
Launch postprocessing file with
DynaWeld temperature scale
Performance analyse
Midpoint by 3 Points
Conversion utilities
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Check of heat input and final adjustment
right energy inputright results
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Conclusion
LS-DYNA
DynaWeld
from Process parameter to solver
keyword input
Material Models representing physics within phase kinetics
Succes in industrial applied
simulation for manufacturing
processes with high sophisticated
phiysical phenomena like
Heat Treatmentand Welding
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DynaWeld GmbH & Co. KG in GründungSchweißstruktursimulationSchweißprozessimulationWärmebehandlungsimulationWerkstoffsimulationProzesskettensimulation
www.dynaweld.de # www.dynaweld.eu
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39Foto: Martin Loose