Detect gap formation during welding with DynaWeld welding simulation
    Thermal expansions already lead to deformation of the components during welding. This can lead to components moving apart at the joining zone. The formation of this gap endangers process stability and leads to significant shape deviations.

    DynaWeld Welding Simulation DynaWeld Material Manager
    Gaps occurring (right) when welding aluminum profiles (left)
    This gap formation is to be limited or prevented with a clamp device. Alternatively, tack welds are used to fix the components. With the Dynaweld welding simulation and the Free Motion Filler method developed by DynaWeld it is possible to analyze this gap formation simulatively. A selected clamping concept can thus be numerically approved in advance. It is also possible to check the draft of a tack weld concept. This means that any high consequential costs of subsequent correction interventions in production can be avoided in advance. The more advanced production planning is, the higher these costs tend to be. In the worst possible case, that would be the production shutdown. This applies not only to undesired gaps, but also to welding distortions in general.
    You can find an example of this in our video DynaWeld Gap-Analysis:

    DynaWeld Incuction
    Induction hardening with DynaWeld

    Induction is an efficient method for targeted heating. Components can be heated both completely and partially. Induction heating can be used for welding, straightening, preheating or for heat treatment.
    We have developed a modeling method to image inductive heating to a 3D model. We use the boundary element method, which means we can do without meshing the air. That makes the application effective.

    With the help of induction simulation, the process (position of the inductor, duration and frequency of the induction current) can be designed and the optimal shape of the inductor can be determined.

    You can find a small application example in our video DynaWeld Induction:

    DynaWeld Induction
    New DynaWeld release available

    With the new version of DynaWeld we have prettied up the appearance of the surface. In addition, the user can now choose the colors of the GUI according to his own wishes. In addition to English and German, DynaWeld is now also available in Spanish. At the customer´s request, we can now enter any language.

    DynaWeld Welding Simulation DynaWeld Material Manager
    New design for the DynaWeld user interface

    Other functionalities:
  • Simplified import of material data from tests, material data sheets or publications
  • Free clamping of tools without additional knot fixings
  • Cumulative deformations in multi-stage simulation. Deformations from several calculation stages are added up so that the total deformation can be represented from the entire production sequence.
    DynaWeld for heavy machinery construction - heat management during welding

    Heavy machinery construction places special demands on the design of welded joints. Solid components with sheet thicknesses between 100 mm and 500 mm absorb the welding heat much faster than thin-walled components. The result is high cooling rates with common welding processes such as gas-shielded metal welding or submerged arc welding. Steels that can be welded in the thin sheet area can suddenly cause problems. This applies in particular to the common structural steel S355. Not every chemical composition permitted by the standard can be welded.

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    Root pass of fillet weld of thick sheets, strength depending on the cooling rate

    Preheating, energy per unit length, chemical composition, conversion behavior, remaining microstructure ... these are the interdependencies between process and material. DynaWeld can use suitable analyzes to determine which structure occurs depending on the material and welding process. In addition, DynaWeld can also make recommendations on the material for a given process.

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    Microstructure depending on the cooling rate

    The question often arises as to whether preheating is necessary, how high it must be, or whether subsequent annealing must be carried out. All of these measures are directly associated with costs. Intelligent heat management and optimal process design with DynaWeld helps to save costs.

    We use WeldWare® when designing the heat management . With DynaWeld® oder Goldak - VrSuite® we can determine heat propagation and temperature fields even for complex geometries. The calculation of heat treatment measures such as stress relieving is also possible.

    heavy machinery construction
    Application example for a successful heat management design.
    Courtesy of HAEUSLER AG, Duggingen, Switzerland.