Finite Element Welding Simulation: RSW, FSW, Arc, Electron and Laser Beam Welding

ESimLab engineers simulate the Welding with innovative CAE and virtual prototyping available in the non-linear structural codes LS-DYNA, Ansys, Comsol, Simufact Welding, ESI SysWeld and ABAQUS. We are experienced with FEA Welding simulation. ESimLab Engineers can simulate any type of welding such as Arc Welding, laser Beam Welding, RSW, FSW and transfer the results of welding simulation for next simulation like NVH, Crash test, Tension, Compression and shear test and fatigue simulation.
Our engineers have strong backgrounds in FEM(Finite Element Method) and complicated Multiphysics simulation that need deep knowledge and are fluent in the codes like LS-DYNA, Ansys, Comsol, Simufact Welding, ESI SysWeld and ABAQUS. We can develop special purpose user subroutine (UMAT) based on clients need to empower simulation environment to overcome any complicated problem in heat load condition and user defined material constitutive equation.

ESimLab Engineers can simulate any type of welding with any level of complexity such as:

Arc Welding
• Electron Beam Welding
• Laser Beam Welding
• RSW (Resistance Spot Welding)
• FSW (Friction Stir Welding)
• Pressure Welding
• Stress Relief Heat Treatment
Fatigue Life of Welded Structures
NVH, Crash test, Tension, Compression and shear test behavior of Welded Structures

CFD and FEA consultant at ESimLab

FEA and CFD Based Simulation

Special Conditions that included in Finite Element (FEA) of Welding Simulation

Welding cause to The components, commonly made of steel(s), are temporarily heated to specific temperatures Distribution. Taking into account the rate of heating and cooling, the material properties of a component can be altered and improved. The presence of certain agents can lead to changes in the carbon or nitrogen content of the component. In all welding processes, there are several decisive and important factors: Time (heating and holding time), temperature, atmosphere, and quenching or cooling conditions. In principle, there are two kinds of welding effect as heat treatment processes on material points:

processes resulting in a thorough change of the microstructure such as annealing and hardening
processes that result in merely changing regions close to the surface of the component such as diffusion and coating processes, carburization, case hardening, nitrating, boriding

The mechanisms used for Finite Element (FEA) heat treatment vary considerably between different groups of materials (Stainless Steel(s), Kovar, Cupronickel, Copper (Cu), Iron (Fe), Monel, Inconel, Nickel (Ni), Titanium (Ti), Moly, Tungsten, Moly-Rhenium, Platinum, and Tantalum), e.g. between aluminum and steel. Therefore, the material group has to be taken into account.

Arc Welding

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.

Laser 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

Electron Beam welding is a thermal joining process, in which a component is heated and welded by electron beam. It is a high-end process for application cases requiring the highest degree of precision. A huge advantage of electron beam welding lies in the relatively narrow heat affected zone.

Stress Relief Heat Treatment

Stress relieving reduces residual stresses in the assembly after welding.The Stress Relief Heat Treatment performed including definition of time-temperature curves for heating, holding and cooling phases with individual convective heat transfer to environment definition. FEA Stress relief is modeled taking into account two mechanisms:
• Stress relaxation due to decreased yield stress of material during heating
• Time-dependent creep properties of the material

Resistance Spot Welding

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.

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.

metal forming simulation: ansys abaqus simufact forming

Mechanical Joining

Forming processes that cause a mechanical interlock between the pieces. Mechanical joining includes riveting methods such as; punch riveting, self-piercing riveting and blind riveting, as well as clinching technologies such pressure joining, clinching and toxing.

Pressure Welding

Pressure welding stands for a group of joining processes in which components are joined by heating and compression. Heat can be generated either via current (resistance welding) or by using friction (friction welding).

Arc Welding Simulation Finite element abaqus ansys sysweld simufact MSC
Arc Welding T Joint Microstructure Welding Finite element abaqus ansys sysweld simufact MSC 2
Resistance Welding Microstructure Finite element abaqus ansys sysweld simufact MSC 4
RSW Welding Simulation Finite element FEA Ansys Abaqus Simufact welding ESI sysweld 2

Considering complexity and needs to have new procedure and constitutive equation, we must try to develop new FEA and CFD based software to overcome engineering challenges.

FEA and CFD based Programming needs experience and deep knowledge in both Solid or fluid mechanics and programming language such as Matlab, Fortran, C++ and Python.

Esimlab’s engineering team use advanced methodology and procedure in programming and correct constitutive equation in solid, fluid and multiphysics environment based on our clients needs.

We use subroutine’s with programming languages such as Fortan, C and Python in CFD and FEA sofware such as Abaqus, Ansys, Fluent and Star-ccm+ to add new capability and Constitutive equation.

ESimLab use Mathematical Methods and Models for Engineering Simulation. We, focuses on numerical modelling and algorithms development for the solution of challenging problems in several engineering sectors specialized in the development of software for the numerical discretization of partial differential equations, linear algebra, optimization, data analysis, High Performance Computing for several engineering applications.

Real world Simulation: Combination of experience and advanced analysis tools

Calling upon our wide base of in-house capabilities covering strategic and technical consulting, engineering, manufacturing ( Casting, Forming  and Welding) and analytical software development – we offer each of our clients the individual level of support they are looking for, providing transparency, time savings and cost efficiencies.
ESimLab engineers participate in method development, advanced simulation work, software training and support. Over experiences in engineering consulting and design development, enables ESimLab’s engineering team to display strong/enormous client focus and engineering experience. The ESimLab team supports engineering communities to leverage CFD-FEA simulation softwares and methodologies. It leads to the creation of tailored solutions, aligned with the overall product development process of ESimLab clients.

CAE Simulation: CFD, FEA, System Modeling, 1D-3D coupling

Integrated expertise covering every Equipment component analysis. From concept through to manufacture and product launch, and for new designs or Equipment modifications, we provide engineering simulation expertise across projects of all sizes. Simulation has become a key enabling factor in the development of highly competitive and advanced Equipment systems. CAE methods play a vital role in defining new Equipment concepts.

metal forming simulation: ansys abaqus simufact forming
Metal Forming Simulation
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Hydrodynamics
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Aerodynamic Simulation
Ansys Fluent, Siemens Star-ccm+ Numeca fine , Avl Fire, Matlab
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MultiPhase Flow Simulation
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Multi-Body Dynamics (MBD)
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Composite Design
welding FEA Simulation Simufact Welding ESI Sysweld Abaqus Ansys ESIMLAB
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