Simufact Welding

Welding Process Simulation Software

Robustly simulate complex multi-station fixturing and assembly of complex assemblies with hundreds of joints. Perform a “virtual tryout” before the first part is fabricated.

Simufact Welding aiuta a simulare complessi processi di saldatura che potrebbero comprendere sequenze di saldatura multiple ed esegue una stima delle distorsioni dei componenti, tenendo conto anche delle trasformazioni di fase che si verificano durante il processo. Con Simufact welding, gli utenti possono comprendere meglio le proprietà del cordone di saldatura e i difetti di saldatura, come le cricche a caldo, così da poter affrontare i problemi prima di mettere in atto il processo.

Grazie all’utilizzo congiunto di Simufact Welding e Simufact Forming, gli utenti possono simulare una combinazione di diverse fasi dei processi di saldatura upstream e downstream. Il semplice trasferimento dei dati consente non solo di tenere in considerazione la storia della formatura, ma anche di analizzare la resistenza delle saldature simulate.

Exactly the right welding process you need

Arc Welding

With the Arc Welding module common arc welding processes are simulated. Residual Stress, strain and distortion as caused by the welding process are predicted. This enables an improved quality and dimensional control.

Simufact Welding allows to evaluate the impact of vaious parameters, like: weld sequence, arc welding process parameters and fixturing strategy.
Multiple weld robots can be configured. Weld fillets are modelled very easily using the internal fillet generator.

Simufact Weldiing makes use of a comprehensive material database that can be extended by the user.

Laser and Beam Welding

Laser- and Electron Beam Welding processes are simulated to predict the local distribution of residual stress, strain and distortion.

Simufact Welding takes into account the specifics of a Laser or Electron Beam heat source. This complements the extensive capabilities that are offered for simulating arc welding processes and enables an accurate prediction of any physical Laser and Beam welding process.

Resistance Spot Welding

With Simufact Welding, Resistance Spot Welding processes are simulated with a high accuracy. The impact of multiple parameters like spot sequence, welding process parameters (force, current, time) and fixturing/clamping strategy on the weld structure is predicted.

The flexible configuration of the simulation in different modes (thermomechanical, mechanical with electrode movement and simplified) enables a fast simulation for complex assemblies.

Laser Metal Deposition

Simufact Welding enables the quick and efficient setup of robust laser metal deposition (DED) models in order to calculate and evaluate for stress, strain, distortion, thermal history, and hot spots during manufacturing and post processing.

Common robot programming such as the G-Code can be utilized - This allows users to simply import existing tool paths instead of defining weld paths manually.

Brazing

Brazing is a thermal process that applies hot soldering material to join parts. The Simufact Welding Brazing module takes care of the specifics of this process: the heat input for example is limited to the soldering material only - the soldering material itself is modelled by fillets.

Brazing simulations can be defined using both conventional and beam heat sources, or a combination of them.

Virtual Clamping

Virtual Clamping enables to predict the exact geometry for parts and assembled structures. Simufact Welding simulates the behavior of parts as they are clamped and welded in their designated (for example: vehicle) coordinates - This dramatically reduces the need for prototypes or tryouts.

Stress relieving reduces residual stresses in the assembly after welding. Usually the application of this heat treatment method involves controlled heating of the assembly, a certain holding period at elevated temperature as well as controlled cooling - The simulation enables virtual tryout to achieve the best possible heat treatment process

Simufact Welding is not only easy to use due to its process-oriented and intuitive user interface, but also includes comprehensive functionality for all simulation steps from modeling to calculation and the evaluation of results.

Besides the full transient thermal-mechanical simulation of spot-welding processes, a solution for pure mechanical simulation is implemented, which allows the user up to 30x faster simulation speed.

Simufact Welding is designed to fit the needs of process engineers rather than CAE specialists. The excellent usability enables a significant reduction of modelling times.

Simulate the welding of two components or even complete assemblies

Simply set the element size and create refinement boxes for particularly important areas if needed, click "Create Mesh" and the meshing will be performed automatically.

Your benefits with Simufact Welding

Design and optimise your welding process:

Determine the optimal weld sequence and parameters, as well as clamping and unclamping concepts, to minimise thermal distortions and residual stresses and ensure a robust welding process.
Identify and eliminate potential welding defects, such as hot cracks.
Investigate material behavior during welding, such as phase transformation.

Simplicity – No CAE expert knowledge required as the software solution is designed to be user-friendly, intuitive and process-oriented.

Sustainability – Save material, time and money by replacing expensive and time-consuming physical tests with virtual tests.

"Simufact Welding helps us find relationship between the applied tool path and the cooling rate, phase transformation, residual stresses and other factors that can determine the quality of the delivered materials."

Dr. Amin S. Azar

Head of Additive Manufacturing,

Effee Induction AS

"For us, the accuracy of the simulation results as well as affordable calculation time are mandatory. The newly developed Advanced Thermal Cycle (ATC) approach looks very promising as it has high accuracy but shorter computation time. We will test the new approach in future projects."

Verena Uhl

Head of Additive,

pro-beam additive GmbH

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Simufact Welding predicts distortions and residual stresses by virtually try‐outs and helps the user to determine appropriate strategies to minimise them...

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