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.
Gaps occurring (right) when welding aluminum profiles (left)
You can find an example of this in our video DynaWeld Gap-Analysis:
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:
New DynaWeld release available
- 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.
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.
New design for the DynaWeld user interface
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.
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.
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.
Application example for a successful heat management design.
Courtesy of HAEUSLER AG, Duggingen, Switzerland.