1 Introducing Simufact Welding

Introducing Simufact Welding About Simufact Welding

Table of Contents
1.1. About Simufact Welding ............................................................................................................... 2
1.2. Understanding welding simulation ................................................................................................... 2
1.3. Structural welding simulation ......................................................................................................... 5
1.4. Best welded strategy ..................................................................................................................... 6
1.5. Overview of the power tools .......................................................................................................... 7
1.6. GUI functions .............................................................................................................................. 9
1.6.1. User interface .................................................................................................................... 9
1.6.2. Settings ........................................................................................................................... 10
1.6.3. Units .............................................................................................................................. 12
1.6.4. Object catalog .................................................................................................................. 13
1.6.5. Process tree ..................................................................................................................... 14
1.6.6. Model view ..................................................................................................................... 17
1.6.7. Advanced functions and hints ............................................................................................. 19
1.7. Help section ............................................................................................................................... 19
1.7.1. Offline help ..................................................................................................................... 19
1.7.2. Online help ..................................................................................................................... 20

1.1. About Simufact Welding

Simufact Welding is a finite element-based software for welding simulations. Finite element calculations are suitable
for modelling the elastic-plastic and hardening material behaviour and, thus, also for simulating welding structures.

Latest solver technology and a user-friendly overall concept allow to calculate welding sequences efficiently and to
predict distortions of the component realistically. In addition to that, phase transformation can also be considered.

The software assists in finding the optimal clamping devices for the welding process and aids manufacturing engineers
to determine the best welding sequence. Simufact Welding predicts the final contour of the component and helps to
produce parts in series with precise tolerance.

Allowing the calibration of combined alternative heat sources in less than 15 minutes, it provides useful tools to that
end.

• Mathematical heat sources (so-called equivalent heat sources) are state-of-the-art to simulate welded structures
faster;

• The question Which welding processes are compatible with your software? becomes secondary, since almost all
common fusion welding methods can be depicted by means of an equivalent heat source geometry.

1.2. Understanding welding simulation

Over the last 35 years, the research field in the area of welding simulation has converged to three main areas with
different requirements to the computationally implemented mathematical and physical models.

Radaj has classified the approach in three interconnected domains:

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 Introducing Simufact Welding Understanding welding simulation

Figure 1.1. Research fields of welding simulation according to Radaj (2002)

The melt pool flow and the resulting seam configuration are not the outcome of welding structure simulations and
are considered as input parameters. The main objective of the process simulation is the prediction of parameters to
be adjusted at the welding equipment. For process simulations it is vital to have a higher resolution which results in
more complex and time consuming calculations. So, this kind of simulations except of resistance spot welding are
usually studied decoupled.

The welding structure simulation calculates the outcomes of heat effect from the welding process on the structure.
Thus the prior knowledge of production factors in different manufacturing processes (laser type, focusing position,
submerged branch, and so on) is not critical. It is more important to model the heat flow out of the melt pool via
mathematical heat sources (e.g. 'equivalent heat sources'). Those will be ideally calibrated according to the weld pool
dimensions which can be observed in a micrography. If necessary, Simufact Welding is capable of working with
combined heat sources, which can be usually calibrated in less than 15 minutes.

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 Introducing Simufact Welding Understanding welding simulation

Figure 1.2. Side-by-side view of a simple model setup and resulting peak temperature

Simufact Welding is especially designed to predict the welding distortions. Through the standard implementation of
predefined materials and material models, the software can calculate structural components and material states and
the resulting local (property) conditions. Phase transformation models consider the transformation strains, plasticity
and martensitic and bainitic hardening.

Distortion itself is not a problem for manufacturing; after all, it is the natural material behavior. When distortions in
welding exert a negative influence on a specific characteristic of a component, then one might get problems. These
distortions have the potential to cause a costly drawback. The technical requirements related to dimensional accuracy
and tolerances for welded components are directly related to the function of the component (suspension arm, chassis,
subframes, wheels, etc.).

The following table gives an overview on these influenced characteristics which could deeply be investigated making
use of Simufact Welding.

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 Introducing Simufact Welding Structural welding simulation

Figure 1.3. Undesirable impacts caused by distortion

1.3. Structural welding simulation

Once the technical requirements are defined, the mesh quality and the adequate post-processing can be defined. The
major inconvenience caused by welding distortion is the challenge to assemble welded components. This task can be
found in all industry sectors. So, the distortion calculation has to focus on the distance of points or on the rotation of
the surfaces to be connected. When gap tolerances are in the focus of the welding simulation, the results need to be
transferable reference positioning systems (RPS). If buckles on the surface have a negative influence on the reflected
light of the coated component, then a high-resolution rendering can help.

The calculation of distortions is neither a solution nor an improvement. But it can help to find useful counteractions
in order to minimize the negative influence of welding distortion by a virtual try-out of clamping concepts, welding
sequence, etc.. Welding simulation can be used at all stages during and after the development process. In early design
phases it can be used to compare different welding processes and strategies with regard to distortions before any
investments for welding equipment has been made. This approach saves a lot of money designing appropriate fixture
system right from the beginning.

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 Introducing Simufact Welding Best welded strategy

Figure 1.4. Comparison of the distortion between

a non-heated and pre-heated welding process

1.4. Best welded strategy

After going through the previous sections, it is clear that the purpose and advantages of Simufact Welding are:

• To calculate the global temperature field

• Show the structural behavior of components

• Present the distortion during and resulting from the welding process

• Visualize the residual stress due to structural changes

• Deliver in details the ongoing process to the user

With Simufact Welding the user is able to:

• Efficiently simulate the important aspects: Using the most realistic representation of components and necessary
real fixture conditions

• Calculate precise results: Configure the optimal welding parameters, knowing in advance where the distortion
will occur and keep stress under control

• Obtain faster solutions: Unleash the power of parallel processing, making use of distributed calculation for rapid
achievements

• Ease of use and flexible changes: Starting from simple models, then highly complex processes considering a
chained analysis of previous results

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 Introducing Simufact Welding Overview of the power tools

• Immediate available tools: All features are readily at hand in a single interface, no command-line interaction is
necessary, just copy-paste and drag-n-drop

1.5. Overview of the power tools

Presenting the interface of Simufact Welding:

Figure 1.5. Simufact Welding main screen - user

friendly interface at the core of development
Here is what you can perform with Simufact Welding:

• All arc welding processes: MIG, MAG, TIG, Submerged arc etc. and combined methods like plasma-keyhole and
LASER-hybrid

• All beam processes: LASER, Electron etc.

• All brazing processes

• Resistance spot welding processes

• Direct energy deposition processes

• Stress relief heat treatment processes

• Simple cooling & clamping process

• Multi-layer welding: Root pass and overlapped joints

• Cladding and deposition processes

• Tack welds with or without filler material

• Quick definition of welding paths using mouse clicks

• Quick definition of heat source orientation: Customized torch angle

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 Introducing Simufact Welding Overview of the power tools

• Quick thermal-only calculation with all metallurgical phase transformation

• Decoupled mode for thermal-mechanical pass independence

• Weld monitor to look at the cross section along trajectories to see penetration depth

• Any combination of welding sequences, direction or time periods

• Easy copy-paste functions to analyse different scenarios, also based on previous calculation steps

• Multiple or single robots/operators simultaneously with time managed separately

• Easiest tool/fixture/clamp definition, simple geometry can be generated inside Simufact Welding

• All types of fixtures can be deactivated during the process to study their interference

• Fully automatic contact calculation between all bodies

• Virtual welding of components with adaptive local contact condition

• Gap formation is calculated intrinsically regarding fixture concept

• Non-conformal mesh is fully supported, there is no need to match or merge nodes

• Friction is automatically applied through included models

• Automatic mesh refinement according to specified criteria

• Filler material creation is fully parametrized and generated inside Simufact Welding

• Weight due to gravity can be part of the simulation

• Phase transformation is calculated using multiphase materials based on CCT and TTT diagrams or based on
Leblond/ Koistinen-Marburger

• Material database with more than 30 materials that could be expanded by the user

• Direct interface with JMatPro for customized material

• Distortion, effective stress, phase transformation and many other results are part of post-processing

• Particles over the structure to be welded serve as comparison with real process in MS Excel format compatible

• Possibility to export results and distorted geometries (STL) at every calculated step

• Universal file format available to import/export results from/to third-party applications

• Multithreading and multiprocessor distributed architecture available at a mouse click

• Flat learning curve, the interface is very user friendly

• And a lot more...

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 Introducing Simufact Welding GUI functions

Figure 1.6. Temperature, distortion and effective stress

are some of the available post-processing variables

1.6. GUI functions

1.6.1. User interface
The image below shows the main screen of a project in Simufact Welding.

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 Introducing Simufact Welding Settings

Figure 1.7. Main screen - overview of the available interaction areas

One can divide this window in six different areas of user interaction:

1. Main tool bar - This is the link for general and user preferences. The most used functions (Save/Open/Show model)
are available as icons.

2. Process tree - Here are all the definitions of the process. It shows in a tree-like definition all the configured processes
for the current project (more than 1 process normally coexist within the same process tree). To change the process
order in the process tree, drag-n-drop a process up or downwards.

3. Object catalog - All the data defined and imported is first stored here. Geometries, materials, weld paths and
temperatures can be found in this part. Despite being stored with the project, the data available here is only part
of the process if it is used in the process tree, if not it will be represented in italic form. To use an object in the
process just drag-n-drop it into the suitable component.

4. Model view - Outstanding graphic view of the current model with shaded edges enables the user to pan, zoom and
rotate using the mouse. Many views can stay opened at the same time, showing models and results side by side.

5. Properties of process (or another selected component) - A resumed version of the process represented using num-
bers and parameters. Shows the solver configuration, simulation time and mesh properties like the number of nodes,
elements and components in use.

6. Control and status bar - Through this bar the user controls the simulation. Start/Stop buttons and further insights
are readily available calling log files and simulation monitor.

1.6.2. Settings
To call the Settings window, click Extras then Settings.

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 Introducing Simufact Welding Settings

Figure 1.8. Settings - The global settings are available through the settings menu

A new window will open and there you can modify all the options to fit your project's needs.

Figure 1.9. Settings window - Customize Simufact Welding to operate your way
• General - Settings - Here you have the option to change language, external text editor and some memory manage-
ment.

• General - Setup options - Under this section you can choose where all the Simufact Welding shortcuts shall be
placed and whether file extension can be assigned.

• General - Environment - This dialog page allows you to configure the general Simufact Welding environment.

• General - Messages/ dialog positions - Here window positions and geometries (size) can be reset and deactivated
messages can be reactivated.

• General - Directories - This part of the settings is where you give directory's to locate System libraries, User
libraries, documentation, examples and User-defined mesh templates.

• Result values - Color legends - This dialog page lets you organize the color legends of the program environment.

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 Introducing Simufact Welding Units

• Result values - Legend assignment - This dialog page lets you define the assignment of color legends to result
values.

• Result values - User-defined results - This page allows you to manage user-defined result values. User-defined
result values are values that are defined by a formula provided by the user. This enables you to derive new result
values from the ones written by the solver.

• View - Graphics - This dialog page lets you define general display settings of the program environment, such as
the display settings of nodes or the color settings.

• View - Result vectors - This dialog page lets you define the representation of arrows.

• View - Movie capturing - In this section you change the movie capturing configuration.

• Units/Unit system - Here lies the coherence of the entire project as Simufact Welding is able to handle different
unit systems regardless of input method. Make sure you read the next section to get acquaintance with Units before
working.

• Licenses - This dialog page gives an overview of the license settings.

1.6.3. Units
The coherence and conciseness of a simulation project lies on the capability of handling different unit systems and
still make all them talk to each other. When using Simufact Welding the user does not have to worry about this as
the software can work with multiple unit systems simultaneously.

Figure 1.10. Unit system and Units - Simufact Welding is

capable of handling multiple unit systems simultaneously

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 Introducing Simufact Welding Object catalog

There are five standard configurations and one customizable set available. Choose your preferable unit system or
change only the units you're used to:

• Simufact default

• International system of units (SI system)

• SI-mm unit system (using millimeters instead of meters)

• Imperial unit system

• United States Customary System

• User-defined unit system

1.6.4. Object catalog

To define a process in Simufact Welding, the project can contain six main catalogs which are listed as:

Figure 1.11. Object catalog window- Here is

where all data is made available for the project

• Geometries - All imported meshes for components, boundary conditions and geometries directly generated for
boundary conditions are placed here. It is possible to import:

• Meshes of the formats *.bdf, *.feb, *.fem, *sfc, *stl for deformable bodies (components and fillers)

• CAD-geometries of the formats *.iges, *.igs, *.stl, *.stp, *.step, *.jt, etc. for rigid bodies (boundary conditions)

• *.unv-files with results and meshes for deformable bodies (components and fillers)

• *.spr- and *.arc-files from Simufact Forming with results and meshes for deformable bodies (components and
fillers)

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 Introducing Simufact Welding Process tree

• Reference geometries (*.stl) can be used for the result transformation

Multiple geometry objects can be added to a assembly for easier and faster positioning of these objects at once.

• Materials - Material data and models are stored in this catalog.

• Temperatures - Initial temperature for components and fillers, settings for contact heat transfer, radiation and emis-
sivity stays in this catalog.

• Trajectories - Definition of weld paths based on picked nodes or from an external file.

• Welding-parameters - Welding process information, parametrization and heat source specification.

• Stress relief - Information about stress relief heat treatment processes.

• Filter - Filter the objects in the object catalog for processes or categories.

A button to show/hide the filter is at the top right of the object catalog area ( ).When this button is activated, the filter
at the bottom of the objects catalog can be used to filter the objects in the objects catalog for processes or main catalogs.

It is possible to rename an object on a catalog either by using the F2 key or from inside the object's properties.

1.6.5. Process tree

In each project in Simufact Welding several objects have to be defined in the process tree to setup a welding model.
The main objects of the process tree are listed below:

Figure 1.12. Process tree window - All the objects participating

on a welding simulation are listed under the process name

• Process - Tree-like view, describing and organizing the welding process for analysis. A single project may include
many processes. The order of processes can be changed by dragging and dropping a process up or downwards. The
button beside the components in the process tree shows and hides the corresponding geometries in the Model

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 Introducing Simufact Welding Process tree

view. If you right click on any geometry in the Model view you will find this button, too. If you right click in the
model view, you might find this button in the Display mode, because some of the model geometries are hidden.

• Context menu of the process - When right-clicking on the process name the following options are available:

• Model view - Open a model view of the selected process.

• Add symmetry plane - Add a symmetry plane to the selected process.

• New components - Add new components to the selected process.

• New boundary conditions - Add new boundary conditions (bearing, fixing, clamping, local joints) to the selected
process.

• New robots - Add new robots to the selected process.

• Insert contact table - Insert a contact table to the selected process.

• Update timings - Triggers the calculation of timings as well as calculation of element sets for thermal cycle
simulations.

• Model check - Checks if there are warnings and/or errors in the selected process.

• Process report - Creates an process report with all essential information about the process.

• Process control center - Opens the process control center, that visualizes the timing of the welding duration and
of the mechanical boundary conditions.

• Open process folder - Opens the process folder in the windows explorer.

• Import results - Import results from another welding simulation.

• Copy/ Rename/ Delete - Allows to copy, rename or delete a process in respectively from the process tree.

• Configure - Opens the settings dialog window of the selected process.

• Expand/Collapse - Allows to expand respectively collapse the selected process or the complete process tree.

• Symmetry plane - Mechanical and thermal boundary plane for symmetric processes.

• Component - Meshed geometry of the structure to be welded. A single process may include a number of components
as needed. Each component is treated as deformable body passive of heat transfer within themselves and with each
other. Every component has to have defined the geometry and mesh, temperature settings and material. Optional
is initial data of phase composition.

• Boundary condition - These are bodies to constrain the structure to be welded. They can be bearings (with planar
movement allowed), fixings (all 6 DOF are restrained) and clamps (bearings that can apply a force). Every boundary
condition has to have defined the geometry (mesh) but they don't participate on heat transfer; in case the user wants
to calculate that, the boundary conditions should be modeled and interpreted as components.

• Local-joint - This feature mimics the existence of tack welds and spot welds for holding specific areas without
the need of two boundary conditions. The user can either pick these points in the model view or import external
reference files. These local joints behave like nodes connected between two (or more) different meshes.

• Robot - Welding robots (or welder) are represented here. A single process may include many robots as needed.
Each robot contains its weld paths, trajectory configuration, sequences and geometry (mesh) for filler. Weld paths
and torch angles can be adjusted here. Every robot has to have weld paths, initial temperature settings and material
for filler (if applicable). Optional is the weld filler geometry (mesh), which can either be generated by Simufact
Welding or imported from an external mesh.

• Particles - Define pre particles before the simulation is started respectively post particles after the simulation has
finished.

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 Introducing Simufact Welding Process tree

• Process parameters - Define the analysis methodology for resolving the model. Here the user has access to addi-
tional settings like total analysis time, time step configuration, parallelization, automatic mesh refinement, friction
model and more.

• Context menu of the process parameters - When right-clicking on the process parameters object the advanced
process parameters can be exported to respectively imported from a xml file.

• Results - This section appears as soon as the solution of a model begins. During the calculation it is updated
accordingly to the actual progress. The user does not have to wait until the calculation has finished to see the results.
In addition to this, the welding monitor is available to show the cross section normal to the weld seam. Optional
tracking points charts are available when configured before running the simulation. There is also an option for
exporting results as universal file (SDRC) (*.UNV), a format which contains all relevant data (selectable).

• View - Load the available results onto the visualization workspace. The results view can be opened by right
clicking on the Results icon and selecting View, by double-clicking on the Results icon or by right clicking on
the process name and selecting Show results. The result value can be changed by clicking on the result value in
the results view. It is possible to open multiple result views of the same or different processes by repeating the
described actions. Multiple views can be synchronized by clicking on in the view.

• History plot - Display result values for components and particles (pre and post) as curves (in a x-y-diagram).

• Welding monitor - Access temperature information at the cross section normal to the weld bead. Very useful
for checking the penetration depth on components according to melting temperature.

• Result transformation - Transform the results to a user-defined coordinate system.

• Shape comparison - Allows to analyze the shape deviation between the final surface mesh of the part and the
initial or another reference surface mesh.

• UNV export - Export results into a universal file format.

• Delete - Delete the results.

• Manage results - Manage results at time step level.

It is possible to add groups in the process tree of a process by right clicking on a object and selecting add to group.
A group can contain several objects of the same type (component, clamping, bearing or fixing). Objects can be added
to an existing group via drag and drop.

Figure 1.13. Grouping of objects in the process tree

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 Introducing Simufact Welding Model view

Figure 1.14. Assessing results - Right-clicking on the

results object makes a new set of options available

The new color schema that shows all objects of the same object type (components, fixings, bearings, etc.) in the same
color makes the model view more clearly.

For a more detailed explanation on each object or catalog, please visit the Help section.

1.6.6. Model view

The model view enables the user to pan, zoom and rotate using the mouse. Right clicking on any component in the
model view opens a context menu with additional tools for displaying or manipulating the component. Analogously
the user can open and manipulate a result view. Many views can be opened at the same time, showing models and
results side by side.

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 Introducing Simufact Welding Model view

A small view control appear in the active window, and when many views are opened simultaneously then this tool
will be extended to involve synchronisation tool.

Figure 1.15. Model view

Figure 1.16. View control

• First one: Select the orientation of the view (home view, Z-X view, bird view, etc.).

• Second one: Store and select user defined views.

• Third one: Reset zoom or zoom to a region.

• Fourth one: View rotation.

• Fifth one: Show and hide view elements (legend, triad, process information and global coordinate system).

• Sixth one: View synchronisation. "Synchronize all the time" in the context menu of this tool will synchronise the
view and all other selected items in the menu all the time for all opened views. This tool only appears in the view
if more than one view is opened.

In the color legend in the model view a number is shown in brackets behind the object types, that shows how many
objects of this type are in the process respectively are currently shown in the view (if some are hidden).

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 Introducing Simufact Welding Advanced functions and hints

Figure 1.17. Color legend in model view

1.6.7. Advanced functions and hints

• Model check: In Simufact Welding it is possible to perform a model check to see what errors or warnings are
present in the model. Simply click on the process name with the right mouse button and select Model check.

• Window management: In case there are many views open in Simufact Welding it is possible to close all views but
remain the active view open. This function can be found in the Window menu.

• File management: It is possible to save a project under a new name with or without results. This can be found in the
File menu. Furthermore it is possible to save a project under a new name without results but with _Run_ directory.
This can be found when using Save project as - With input data....

• Reset zoom: Double-clicking on the middle mouse wheel will easily reset the zoom and center the model.

• Multi-selection of geometries in the object catalog: This allows multiple assignments of geometries to reference
geometries and assemblies in the object catalog. Additionally it allows multiple assignments to a process. For vol-
ume meshes components will be created and bearings for surface meshes. Additionally, multiple volume meshes
can be assigned to a robot.

1.7. Help section

1.7.1. Offline help
When installing Simufact Welding by choosing to install the accompanying documentation, you will be able to count
on a comprehensive set of help files. These files are the offline help you get instantly by accessing the Help section:

Figure 1.18. Offline help - Available documents for consulting

• What's new document - This is related to the improvements since the last release.

• Release notes document - Listing all important features added to current version.

• Installation instruction document - Gives an overview on how to install Simufact Welding and start it for the
first time.

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 Introducing Simufact Welding Online help

• InfoSheets folder - Here the user gets a more detailed explanation on important features of Simufact Welding.

• sfMarc folder - Extensive documentation of the solver.

• Tutorial folder - Documentation and tutorial for different process types as well as model setup and post processing.

These files are stored under <installation path>\simufact\welding\<version>\doc

1.7.2. Online help

In case you cannot find a solution for the issue you are experiencing, need support or check for available training
courses, please contact by phone or email your local reseller or the MSC Software office. Local resellers can be found
on our website:

www.simufact.com

We are ready to help you within a small time frame!

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