New materials and lightweight challenges! Analysis solutions supporting welding distortion and quality.
We provide both solutions for "deformation analysis," which can be easily analyzed even with large-scale models, and "welding quality analysis," which details the behavior of metal materials under heat.
ESI provides a total solution to support both deformation and quality issues in the welding process. By dividing the challenges in welding into deformation and quality, we achieve efficiency and high quality in the welding process through solutions tailored to each issue. Additionally, we can perform welding deformation analysis considering the history of press forming analysis and fatigue strength evaluation taking into account the manufacturing process. ◆SYSWELD: Solving "welding quality" issues by analyzing the behavior of metal materials in detail through heat This software uses finite element method for thermal elastic-plastic analysis and conducts coupled analysis of heat, phase, and structure. It faithfully reproduces phenomena occurring during the welding process, such as the movement of the welding heat source, expansion and contraction due to heating-cooling temperature history, and phase transformation, outputting important information for welding quality evaluation, including phase distribution and residual stress. ◆Visual Assembly: Easily analyze large-scale models to solve "welding deformation" issues It enables fast and low-load analysis. Large-scale models can be analyzed in a short time, effectively supporting trial and error in considerations such as welding sequence. Changes in the order of spot welding and clamp positions can be analyzed, allowing for the examination of welding plans with minimal deformation before the prototype stage. *For details, please refer to the catalog available for download below "PDF Download."
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■Other Application Examples ◆Assembly Analysis Using Results from Press Forming Simulation In spot welding assembly of press-formed parts that include errors, overall deformation occurs due to the constraints of heat input from spot welding and the gap between the sheets. By coupling with ESI's press forming analysis software PAM-STAMP, it is possible to simulate welding deformation that follows the results of press forming simulations. The shape obtained after springback from the press forming simulation can be imported, set up in the fixture, and analyzed more accurately through a series of processes including deformation correction (clamping) and welding execution. ◆Fatigue Strength Evaluation Considering Manufacturing Processes The performance of the final product is greatly influenced by residual stresses from press forming and phase transformations and residual stresses from welding. By taking into account the predicted welding deformation, it is possible to reproduce welding with pre-strains such as reverse bending before welding, allowing for prior verification of whether the desired shape can be achieved.
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◆Ford utilizes virtual prototyping to enhance lightweight performance This spot welding fracture solution allows for accurate predictions of the resistance spot welding process and enables a seamless transition from manufacturing results to performance models. As a result, the fracture characteristics of spot welding, which previously required individual software for each process, can now be evaluated in a single environment. In spot welding of high-strength steels like boron steel, the nugget becomes completely martensitic. In the heat-affected zone, softening occurs due to the transformation from existing martensite to tempered martensite. ESI's spot welding fracture solution seamlessly captures phase information after welding and changes in mechanical properties around the weld, allowing for the prediction of fracture force-deflection curves through overlapping shear and cross tension. <Comment from Niels Pasligh of Ford> "The benchmark created jointly by ESI and Ford has improved prediction accuracy and process efficiency by seamlessly linking the welding fracture prediction process with manufacturing and welding fracture performance, achieving a user-friendly virtual assessment."
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ESI Group is a leading company in "virtual prototyping," providing innovative solutions and services focused on "materials physics." We have developed unique solutions that enable the replacement of physical prototypes and experiments with virtual design, manufacturing, assembly, testing, and evaluation. Leveraging today's cutting-edge technology, ESI's virtual prototyping addresses performance evaluation throughout the product lifecycle, from the start of use to the end of life, proposing a broader concept: Product Performance Lifecycle (TM). This is achieved by creating a Hybrid Twin (TM) that utilizes simulation, physics, and data analysis, allowing for smarter product development, maintaining a connection with the actual product, and enabling performance predictions and maintenance timing throughout the product's usage period.
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