Validation tests for the welding simulation
DynaWeld at the Technology Institute for Metal & Engineering GmbH (TIME)
The prediction accuracy of numerical simulations can only be convincing if the models used are suitable for the physical processes and the modeling is realistic. A check can be done on the basis of welding tests. So far, one can find in the literature for verification purposes many simple components such as blind seams on sheet metal or a simple T-joint. Industry-relevant assemblies are hardly found there. DynaWeld has successfully performed simulation comparisons for many of its customers in the past, but these are confidential and shall not be made public. With a common research project, the Technology Institute for Metal & Engineering GmbH (TIME) in Wissen / Sieg, Germany, Goldak Technologies Inc. in Ottawa, Canada and DynaWeld GmbH & Co. KG in Wössingen, Germany, are planning to demonstrate the prediction accuracy of the welding distortion calculation on industrial components. The research project is carried out by all project partners in personal contribution.
test realisation on 22.10.2019 at TIME
When welding the orthotropic plate, all process steps occurring in production are mapped. After tacking, the stiffeners are welded to the base plate. Single-layered and multi-layered fillet welds in horizontal position as well as pendulum welded seams are used. In the project, not only the final distortion is examined, the distortion development is also considered. At five selected points, the deformation that occurres during welding is measured continuously and can therefore be compared with the calculation. The aim of the project is to show that not only the final distortion can be calculated correctly, but also the entire deformation process during welding.
The test procedure is particularly challenging for the robot controller. The large distortion in welding must be taken into account in the path programming of the robot. A challenge that was mastered.
DynaWeld auf der INSIGHT @ Volkswagen Wreśnia 2019
INSIGHT @ Volkswagen Wreśnia 2019 was hosted by the Automotive Circle and took place in Poznan. Highlight: Visit to the new VW plant for the Crafter in Wrenia. In addition to many interesting lectures on body construction with a focus on commercial vehicles, DynaWeld is contributing to digitalization in production planning:
Distortion managemnt in the design of the assembly of body in white
DynaWeld at the Day of Welding Practice in Rostock
DynaWeld presented its software solutions again this year at the Day of Welding Practice in Rostock. There was also the 25th anniversary of the organizer, the SLV Mecklenburg-Vorpommern. Congratulations on this!
DynaWeld meets Goldak Technologies
DynaWeld spent a week with John Goldak and his team in
Ottawa, Ontario, Canada. In addition to intensive expert talks, discussions were held on how welding simulation and heat treatment simulation can be used even more efficiently in the future and how small and medium-sized enterprises can also benefit from it. VrSuite offers a variety of functionalities developed by Goldak specifically for the simulation problems of welding and heat treatment. These include, among other things, special meshing automatisms for welds. Multi-layer welds with multiple passes per layer can be automatically modeled using WPS data. With the new Goldak heat source WeldPoolQS, the cross-sectional geometry of the individual weld pass and their heat input is calculated directly from the process parameters and transferred to the global simulation model.
John Goldak and his team from Goldak Technologies with Tobias Loose
How do I build simulation models, which seam types and processes can be modeled, how do I take into account tack welds or clamping devices... In order to bring the wide range of applications closer to the user, Goldak Technologies and DynaWeld develop together training tutorials on industry-related assemblies and for industry-relevant questions.
Skyline of Ottawa viewed from the Ottawa River
VrSuite, the welding and heat treatment software from John Goldak can be obtained directly from DynaWeld.
Automotive Circle - Joining in Car Body Engineering 2019
In Bad Nauheim (Germany) this year´s conference, organized by the Working Group Automotive Circle, tooke place from 9 to 11 April 2019. In front of an international audience, DynaWeld talked about numerical distortion compensation solutions in BIW constructions. The presented method was developed together with Niels Koch from Opel Automobile GmbH: Digital distortion compensation solution for BIW assemblies by reverse simulation of joining process influences.
Studiennamiddag 3 AUTOLAS: Lasmallen, vervorming en lasparameter
Vim Verlinde from Institut Belge de la Soudure (IBS) / Belgisch Instituut voor Lastechniek (BIL) invited DynaWeld to participate in a workshop on welding distortion welding process parameters with two lectures. One lecture deals with the prediction of weld geometry by calculation: Can we predict weld geometry by simulation?. The second lecture explains how the welding simulation helps to accelerate production times decisively: Can simulation speed up your manufacturing time?. For this presentation we were happy that John Goldak (Goldak Technologies Inc.) joins us as co-author. The fully booked workshop took place in the exhibition halls of EXPO Brussels as part of the MACHINEERING trade fair.
DynaWeld visits UIT Solutions in Seoul, Korea
DynaWeld spent a week at UIT Solutions in Seoul, Korea. UIT organized a total of nine informative meetings on welding simulation and heat treatment simulation at Korean industrial plants and research facilities in the aerospace, rail vehicle, energy and automotive industries. A total of 80 participants showed great intreas about DynaWeld´s solutions for pre-production and production-accompanying simulation of thermal processes.
UIT President Steve Kim, UIT sales managers John Park and Jason Kim with Tobias Loose
Technical work group on cold forming of modern steel materials
For the first time, the work group of the IBU –the Sheet-metal forming industry association– held a meeting in Southern Germany at the company Walter Neff GmbH in Karlsruhe.
DynaWeld presented here a method for the holistic, simulative consideration of the assembly of formed sheet metal components. The aim of this approach is to achieve a minimal form deviation at the end of the production chain. Although high-strength steel materials allow a maximum saving of material, they are thereby susceptible to welding distortion. This is accompanied by a reduction in the component stiffness.
You can take a look on our presentation hier here.