DynaWeld® Feature and Capability


DynaWeld from 23.06.2018
DynaWeld is a pre-processor and simulation environment for finite element application on
  • Welding
  • Heat Treatment
  • Forming
and allows an efficient setup of high sofisticated simulation models for single or multiple manufacturing steps with in the assembly of components.

Languages:
German
English


Supported solvers / FE-codes:
  • LS-DYNA
Requested software aditionally to perform entire simulation:
  • MS-Excel or Libre office
  • Meshing software
  • LS-PrePost
DynaWeld spreadsheet fomat
EU-format with float separator comma and field separator semicolon
UK-format with float separator point and field separator comma
Both formats can be converted vice versa.

Simulation capabilities of DynaWeld

Materials
  • Aluminium and aluminium alloys
  • Steel and steel alloys
  • Nickel and nickel alloys
  • Copper
  • other metals
  • Glass
Welding processes
  • Arc welding: GMAW, SAW, TIG
  • Laser welding
  • Electron beam welding
  • GMAW/Laser-Hybrid welding
  • Resistance welding
  • Resistance spot welding
  • Brazing
  • Tack welding, single pass welding, multi pass welding
  • single robot welding
  • multiple robot welding
Heat Treatment processes
  • Pre heating
  • Quenching
  • Tempering
  • Press hardening
Forming / Tooling (Clamps)
  • forming processes
  • clamp closing
  • clamps with displacement driven kinetic
  • clamps with force driven kinetic
  • prestress
  • predeformation
  • grinding or cutting
Load
  • Force
  • Displacement
  • Pressure
  • Dead load
Porcess chain / assembly simulation
  • Import of initial state (dynain format)
  • Dublicate and prepare model for next stage within initial state, add parts or tools
  • Export of final state (dynain format)
Supportet analyses
  • thermal only analysis (Solids, Shells, 2D shells)
  • thermal mechanical analysis with decoupled calculation (Solids, Shells, 2D shells)
  • thermal mechanical analysis with coupled simulation (Solids, Shells, 2D shells)
  • electro-magnetic thermal mechanical analysis (joule-heating) (Solids)
DynaWeld Modules
  • DynaWeld Material
  • DynaWeld Trajectory
  • DynaWeld Analyse Controler with DynaWeld process input
  • DynaWeld Tools
DynaWeld Material

Data input or import of material data
Material data adjustment
Data extensions for welding and heat treatment
Single phase material for thermal, mechanical, and electro-magnetic analysis.
Multi phase material model for mechanical analysis.
Supported data source
  • user defined data inclusive user defined cct data
  • Weldware
  • SysWeld
  • JMatPro
Data adjustment
  • adjustment of flow curves by yield and tensile stress
  • extrapolation of flow curves for discrete phases from basic data
  • adjustment of minimum or maximum young modulus
  • automatic calibration of CCT data
  • settings for not yet deposit material (filler) or molten material
  • adjust data to fixed temperature and strain scale depending on material group (steel / aluminium)
Data extension
  • Latent heat for melting
  • Initial plastic strain
  • Additional phases (base material, liquid material, tempered phases, heat affected phases)
  • Hardness calculation
  • Damage evaluation criteria
Single Phase Material

mechanical, thermal, electro-mechanical material
LS-DYNA Material *MAT_CWM (*MAT_270), *MAT_CWM_THERMAL, *EM_MAT_001
  • latent heat for melting
  • isotropic, kinematic or mixed isotropic kinematic hardening
  • initial strain
  • simplified approach for phase transformation strain (alpha - gamma transformation steel)
  • electrical resistivity only
  • evaluation of cooling rate
  • temperature constant density
Multi Phase Material

mechanical material
LS-DYNA Material *MAT_GENERALIZED_PHASE_CHANGE (*MAT_254)
  • isotropic hardening
  • initial strain
  • multi phase with phase transformation description by generalized JMAK law and Koistinen Marburger law
  • phase transformation strain
  • phase transformation latent heat
  • hardness
  • yield evolution, elastic and plastic stress utilisation level
  • temperature constant density
Display generated material and its properties in spreadsheet with diagrams.

DynaWeld Trajectory

The trajectories define the weldpathes in the model
Evaluation of trajectory lenghts
Evaluation of number of elements on trajectory
Visualisation of trajectory with start point and reference

DynaWeld Analyse Controler with process input

Model features (process input)

Welding, Weld heat source

Equivalent heat source to cover all weld processes by equivalent heat input method:

Heat sources on shell and solid with or without forced heat input per unit time
Elipsoidal heat source (Loose, Rohbrecht, Goldak, SimWeld, Mokrov)
Konical heat source (Loose, Rohbrecht)
Cylindrical heat source

Heat source on shell 2D-shell and solid surface
Elipsoidal heat source (Loose)
Rectangular heat source (Rohbrecht)

Metatransient heat source
on shell 2D shell or solid part on surface

Geometric heat source adjustment: rotation around trajectory, lateral offset, offset in reference direction

Trajectory definition with two node sets defining trajectory and reference
Trajectory definition with one node set defining trajectory, refererence automatically adjusted normal to surface

Calibration of heat input by global calibration factor of each weld
Calibration of heat input by time function globally or for each weld separately

Up to 1000 heat sources in one simulation model (one stage)
Multiple weld roboter

Heat treatment
Heating, quenching, air cooling, tempering
Quenching medium, function for heat convection vs. temperature
Diving, define diving direction by vector or two nodes
Heating in oven and tempering simulated by heat exchange on surface or by applied foreced temperature-time curve
Autodetect of surface of entire model or user defined quenching surface

Case hardening (carburisation) and inductive hardening (inductive heating) is not included

Time stepping

Implicit, explicit or mixed implicit-explicit mechanical analysis
Timestep fine adjustment for thermal-, mechanical- and EM-solver
Automatic calculation of minimum requested time stepe vs. time for all solvers
Automatic or user defined time stepping for heat treatment process Boundary conditions, loads, movements, temperatures, electrical boundaries

Thermal and mechanical boundary conditions can be applied with birth and death functions. This means bcs can be switched on at time a and switched off at time b.

thermal
Initial temperature on all nodes
Initial temperature on node sets / part of the model
Imposed temperature (trapezoidal function or user defined tabulated data)
Heat transfer to environment, convection
Heat radiation to environment

mechanical
Singel point contraints (SPC)
Displacement on nodes and rigid parts (constant, trapezoidal function or user defined tabulated data)
Force on nodes and rigid parts (constant, trapezoidal function or user defined tabulated data)
Pressure on surface (constant, trapezoidal function or user defined tabulated data)
Elastic spring (no birth death option)
Dead load (gravity)

Force, Displacement and SPC consider global or local coordinate systems
The kinematic of clamps and the kinematic for tools for forming are defined by these mechanical boundary features.

electro-mechanical
Potential (voltage) (constant, trapezoidal function or user defined tabulated data)
Isopotential
Current (ampere) (constant, trapezoidal function or user defined tabulated data)

Parts

Shells, thermal thick shell
Solids (penta, hexa, tetraeder)
2D-shell axissymmetric
2D-shell plane strain
Beams
Define of node sets, segment sets, element sets (shell, solid, beam), part sets by parts

Contact

mechanical contacts:
Friction contact (2D, 3D)
Tied contact (2D, 3D)
Welding contact (3D)
Shell edge to solid tied contact (3D)
Friction contact for all parts against all parts of one part set automatic

thermal contacts:
heat conduction contact (2D, 3D)
quasi tied contact (quasi perfect heat conduction) (2D, 3D)
Welding contact (3D)
Shell edge to solid quasi tied contact (3D)
heat conduction contact for all parts against all parts of one part set automatic
The heat conduction contact can be applied with constant heat conduction or with pressure and or temperature dependend heat conduction

Electrical contacts:
Thermal and pressure dependent electric resistance contact using Jonny Kaars law. )

Simulation settings

Erase of element at discrete time (grinding, cutting)
Static analysis
Dynamic analysis (takes mass into account)
General or selective mass scaling (explicit analysis)
General time scaling (explicit analysis)
Result export for input in next simulation step full model or part of model including temperature, deformed geometry, residual stress, phase proportion and contact status
Springback stabilisation
Output settings

Analyse controler

Clean functions:
  • delete input
  • delete result
  • delete stored postprocessing prints
Genereate solver input in structured folders
Generate solver input in one file
View log files for solver input generation

Electro-thermal-mechanical coupled analysis
thermal-mechanical coupled analysis
thermal-mechanical decoupled analysis (run first whole thermal then whole mechanical analysis)
thermal only analysis
mechanical only analysis (on prior calcualted thermal results)

run simulation
view analysis log file

DynaWeld Tools

Model preparation
Dublicate model
  • dublicate and prepare for next stage simulation
  • dublicate for variant simulation
  • dublicate for mechanical variant simulation, dublicate thermal results
Clean mesh file by delete of empty lines
Import mesh in abaqus format
Source existing LS-DYNA keyword file and prepare for DynaWeld analysis. Existing keywords which do not conflict with DynaWeld are kept in DynaWeld
Clean and merge initial mesh and keyword files

Postprocessing
Launch LSPrePost with predefined scala and DynaWweld colors
  • thermal results steel scala temperature
  • thermal results aluminium scala temperature
  • mechanical results steel scala temperature
  • mechanical results aluminium scala temperature
  • mechanical results stress scala Neg-Pos
  • mechanical results Phase proportion scala Pos
Launch LSPrePost with interface results (contact status)
Launch LSPRepost with user defined command file executed
Automated postprocessing of results on pathes by predefined node sets (result over path-length)
Automated postprocessing of results on nodes by predifined node sets (result over time)

Model evaluation
Evaluate heat input
Evaluate heat input averaged for each weld in case of sequence welding, not simultaneous
Grafical display of heat input
Caclulate calibration function for heat input
Evaluate results on electro-magnetic analysis
Perfomance analysis thermal and mechanical solver (iterations, steps and calculation time versus time in simulation model)

Converter
Convert all result files (*.dat) generated from LSPrePost from UK format to EU format (float separator point to comma)
Convert all csv files from UK format to EU format
Convert all csv files from EU format to UK format


Other tools
Show DynaWeld Environment variables
Switch language
Check License

System requirements

Windows compatible PC
Linux 32 bit or 64 bit
Monitor minimum resolution 1920 x 1080

Installation and Licensing

DynaWeld can be installed in single user mode (administrative rights are not required). The software is licensed via a dongle, which is connected to a USB port.