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ESI Group 10 New Release of the Welding Simulation Suite Distortion Engineering V2010 / Sysweld V2010 / Visual Environment V6.5 The ESI Weld Team
Transcript

ESI Group

10

New Release of the Welding

Simulation Suite

Distortion Engineering V2010 / Sysweld V2010 /

Visual Environment V6.5

The ESI Weld Team

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Copyright © ESI GROUP

Date: 13th of November 2010

Subject: New Releases for the Welding Simulation Suite of ESI

Distortion Engineering 2010, SYSWELD 2010 and VISUAL WELD 6.5

Dear valued customer,

In this document, you will find a summary of the new releases within the Welding Simulation Suite.

We appreciate your continuous interest in our products and services.

Best regards,

The ESI Weld Team

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Copyright © ESI GROUP

CONTENTS

The Welding Simulation Suite - Available Packages .......................................................................................................... 5

The Welding Simulation Suite - Available DVD’s ............................................................................................................... 6

PAM-Assembly and Weld Planner Package .................................................................................................................. 6

Welding Simulation SUITE 2010 DVD – Distortion Engineering ............................................................................... 6

Welding Package ........................................................................................................................................................... 6

Sysweld V2010 DVD .................................................................................................................................................. 6

Visual Environment V6.5 DVD .................................................................................................................................. 7

Visual Mesh V6.5 ...................................................................................................................................................... 7

Visual Weld V6.5 ....................................................................................................................................................... 7

Visual Viewer V6.5 .................................................................................................................................................... 7

What’s New ....................................................................................................................................................................... 8

Weld Planner Package .................................................................................................................................................. 8

Welding Package ........................................................................................................................................................... 8

Enabling Virtual Welding Engineering ...................................................................................................................... 8

More Improvements in Bullet Points .............................................................................................................................. 15

Weld Planner Package (Shrinkage Method) ........................................................................................................... 15

PAM-Assembly Package (LocaL-global Method) .................................................................................................... 15

Welding Package (Transient Method) .................................................................................................................... 15

Language ......................................................................................................................................................................... 16

Toolbox CD ...................................................................................................................................................................... 16

Users Guides and Getting Started Manuals .................................................................................................................... 16

Step-By-Step Tutorials ..................................................................................................................................................... 16

Engineering Guide ........................................................................................................................................................... 16

Online Manuals ............................................................................................................................................................... 17

Online Help ...................................................................................................................................................................... 17

More about the Distortion Engineering DVD .................................................................................................................. 18

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Copyright © ESI GROUP

Pre-Computed Examples ................................................................................................................................................. 20

More on Post Processing ................................................................................................................................................. 20

Visual Viewer Starting from V5.5 ................................................................................................................................ 20

Getting More Information ............................................................................................................................................... 24

Release Notes ............................................................................................................................................................. 24

Highlights of the Present Release ............................................................................................................................... 24

The Welding Simulation Solution – Information for Research & Development ......................................................... 25

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Copyright © ESI GROUP

THE WELDING SIMULATION SUITE - AVAILABLE PACKAGES

The Welding Simulation Suite includes the following packages.

What you can do with those packages is described in more detail in the following document. Please contact your

local dealer to get a copy.

How to achieve your goals

Available simulation packages

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Copyright © ESI GROUP

Preparation of the CAD model

Distortion Engineering – Quick evaluation

Distortion Engineering – Process security

Material data management

Weld Quality – Fabrication details

Spot Welding

Distinctive Competence

THE WELDING SIMULATION SUITE - AVAILABLE DVD’S

The Welding Simulation Suite includes the following DVD’s.

PAM-ASSEMBLY AND WELD PLANNER PACKAGE

WELDING SIMULATION SUITE 2010 DVD – DISTORTION ENGINEERING

WELD PLANNER V2.0

Fast Distortion Engineering based on a shrinkage method, including pre-processing, solver and basic post-processing.

CAD reading and meshing are done with VISUAL MESH. Advanced post-processing is done with VISUAL VIEWER.

PAM-ASSEMBLY V5.0

Precision Distortion Engineering and Weld Quality & Residual Stresses for local models, based on the local-global

method, including pre-processing, solver and post-processing. CAD reading and meshing are done with VISUAL MESH.

WELDING PACKAGE

SYSWELD V2010 DVD

The Heat Treatment & Weld Quality Simulation solver including all physics, in particular transformation of phases

and mechanics including the effects of phase transformations. CAD reading and meshing are done with VISUAL MESH.

The weld simulation is set up with VISUAL WELD. Post-processing is done with VISUAL VIEWER.

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Copyright © ESI GROUP

The traditional Graphic User Interface is still available to allow access to functionalities that have not yet been ported

to VISUAL ENVIRONMENT.

VISUAL ENVIRONMENT V6.5 DVD

VISUAL MESH V6.5

VISUAL MESH enables CAD import and meshing.

VISUAL WELD V6.5

VISUAL WELD enables the definition of the Welding Process and the solution management.

Attention: VISUAL WELD requires the Sysweld solver V2010.

VISUAL VIEWER V6.5

VISUAL VIEWER allows Multi-physics Post-Processing with result comparison and synchronized animations of different

result quantities.

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Copyright © ESI GROUP

WHAT’S NEW

WELD PLANNER PACKAGE

The graphic user interface has been ported to 64 bit windows platforms.

A new solver – the virtual performance solver – has been plugged in.

The solver runs in DMP for multiple processors. The speedup is illustrated hereafter.

The result file size has been reduced by a factor of 5.

WELDING PACKAGE

ENABLING VIRTUAL WELDING ENGINEERING

A co-operation with SLV Rostock / SLV Munich and the software WeldWare enables you to perform Virtual Welding

Engineering.

0

50

100

150

200

250

300

350

400

450

1P 4P 8P 16P 32P

TIME (mn)

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Copyright © ESI GROUP

WELDWARE

WeldWare is a modular welding advisory system, which serves for the calculation of heat procedures in welding.

With Weldware you can generate and validate the process parameters you need to perform distortion engineering,

weld quality and residual stress analysis for complex structures.

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Copyright © ESI GROUP

WeldWare allows to;

Calculate schematic welding – TTT diagrams according to the chemical composition

Calculate microstructure in the heat affected zone depending on chemical composition and cooling time

Calculate hardness, yield strength, tensile strength, elongation, reduction of area and impact values in

dependence of chemical composition and cooling time

Consider scatter of charges during determination of mechanical properties or cooling times

Calculate the true material composition in multi-pass welds, pass by pass, depending on base and wire

materials, and calculate the properties of the material mix

Determine the necessary heat input and pre-heat temperature. This works as well for aluminum, titanium,

nickel and (high) alloyed steels

Calculate the cooling time in dependence of welding process, welding parameters, pre-heating temperature,

joint type and material thickness

Once process parameters and properties are validated, the generated data serve as basis for simulations on complex

structures. The following tools help to complete the information needed for transient welding simulations.

STRAIN HARDENING CALIBRATION TOOL

The strain hardening tool helps to generate engineering data, depending on temperature and phases. Data for

austenite depending on the carbon content is hard-wired.

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Copyright © ESI GROUP

PHASE TRANSFORMATION CALIBRATION TOOL

The phase transformation tool helps to calibrate iso-thermal and continuous phase transformations. It makes use of

the SYSWELD solver to compute the required data – automatically. You need to enter only engineering data.

The results, for example a CCT diagram - can be displayed as follows.

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Copyright © ESI GROUP

MATERIAL DATA MANAGER

The material data manager allows composing a material database for SYSWELD. You deal only with data in Microsoft

Excel . Thermo-physical properties of all common steel classes are hard wired. The result is a database in SYSWELD

format, including all data necessary to perform transient analysis.

NEW GRAPHIC USER ENVIRONMENT TO SET UP AND RUN WELDING SIMULATIONS

VISUAL-WELD has been designed with the objective to give you an easy access to more than 100 man-years of

experience in welding simulation. Running the SYSWELD solver, VISUAL-WELD offers the best possible combination of

user-friendliness and result quality.

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Copyright © ESI GROUP

SOLVING HUGE MODELS WITH A DISTRIBUTED MEMORY PARALLEL VERSION IN A REASONABLE TIME

FRAME

A DMP version is available for Linux computers. It allows solving problems in a fraction of the time, especially larger,

more element intense, models. Below you can see an illustration of the speed up over the number of processors.

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Copyright © ESI GROUP

The DMP solver will be available in Windows in the next release of Visual Weld V7.0.

0

2

4

6

8

10

0 4 8 12 16 20 24 28 32 36

Nbr Processors

Sp

eed

Up

CPU SYSWELD

ELAPSE SYSWELD

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Copyright © ESI GROUP

MORE IMPROVEMENTS IN BULLET POINTS

WELD PLANNER PACKAGE (SHRINKAGE METHOD)

Separation of components allows a more precise simulation of differences in weld sequences

Vastly improved weld sequence definition

PAM-ASSEMBLY PACKAGE (LOCAL-GLOBAL METHOD)

Multi – Pass analysis is now possible

Structural stiffeners can be included

New sequence manager

Distance measurements to the initial structure / defined planes

WELDING PACKAGE (TRANSIENT METHOD)

The performance of Viscous-plastic post weld heat treatment has been improved

There is a collector manager to generate all required collectors

Weld trajectories are generated automatically

The weld path display has been improved

The weld sequence can be displayed

There is a possibility to automatically generate reports

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Copyright © ESI GROUP

LANGUAGE

The language of the software is exclusively English.

TOOLBOX CD

The Toolbox CD contains Users Guides, Tutorials, and the Engineering Guide. It is delivered together with the SYSWELD

CD.

USERS GUIDES AND GETTING STARTED MANUALS

User’s Guides and Getting Started Manuals are available for all elements of the Welding Simulation Solution. These

guides are integrated within the software, on the software CD and they are located in the chapter ‘01_Users_Guides’

of the Toolbox CD. The User’s Guide of the WELD PLANNER and PAM-ASSEMBLY are included in the Distortion

Engineering DVD.

STEP-BY-STEP TUTORIALS

Systematical tutorials are available for most elements of the Welding Simulation Solution. They are situated on the

toolbox CD, in the chapter ‘02_Tutorials’.

ENGINEERING GUIDE

SYSWELD includes an Engineering Guide that covers decades of experience. This is not to be confused with the usual

Users Guide. Rather than dealing with the usage of the software, it deals mainly with the translation of real cases

into a simulation model. It covers and explains the major simulation engineering knowledge as well as pitfalls related

to

The Finite Element method applied

The simulation engineering ground

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Copyright © ESI GROUP

The Engineering Guide shows the most effective and thus cost effective ways to solve Industrial problems. The

arrangement of the chapters proceeds in the sequence of a typical study. The Engineering Guide is done in a way

that it can be easily read and understood. Pre-condition is a standard engineering education.

Need to know ‘how to’ - you will get the answers

From engineers for engineers

Including detailed Engineering Guidelines and study specifications / quality control documents

The fields covered are

Most Important

Templates

Meshing

Material Properties

Process Parameters

Clamping

Computation

Post-Processing

Simulation Methodologies

Exceed Speed-Up

Access to the Electronic Manuals and the Online-Help

How to get Info from the Manuals

Literature Sources

FEM Course

Theory

Installation Tips

Microsoft Excel® Tools

Tools

ONLINE MANUALS

The SYSWORLD software includes an extended set of electronic manuals. It covers the procedures how to use the

software, but not the engineering part of the problem solution. The manuals can be split in manuals dedicated to

Heat Treatment, Welding and Welding Assembly, and manuals dedicated to the generic usage of the software. The

amount of manuals is huge. Please refer to the chapter ‘12_Access_E_Manuals_Online_Help’ in the Engineering

Guide, to get access. The customer can print his own set of manuals through Acrobat Reader. The printout covers

certainly more than 2000 pages, depending on the manuals chosen. A printed set of manuals can be offered to the

customers. Due to reasons of logistics, it is preferred that the user prints his own and individual set of manuals,

depending on his needs.

PAM-ASSEMBLY includes an online manual.

The WELD PLANNER does not include yet an online manual. It is however so easy to use that it appears not mandatory.

The User’s Guide shows how to use it, it comes with the installation.

ONLINE HELP

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Copyright © ESI GROUP

The SYSWORLD software includes an extended Online Help. Within the Advisors, you get additional help dedicated for

the Advisor Usage.

PAM-ASSEMBLY includes an online help

The WELD PLANNER does not include an online help – it is very easy to use

The Microsoft Excel® tools do partly include a basic online help – they are as well very easy to use.

MORE ABOUT THE DISTORTION ENGINEERING DVD

On the desktop, after the installation, you will find an orange Icon.

Double-click on this icon. You will find the following.

Double-click on WeldingDE 2010.0

Start PAM-ASSEMBLY or the WELD PLANNER with double-clicking on the icons. Get more information on the installation,

and on how to manage license keys with double-clicking on ‘Readme Welding DE 2010.0’.

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Copyright © ESI GROUP

Attention: The SYSWELD solver is installed again, even if it has been already installed somewhere else. There is thus no

need to set any variables or links. It will just work.

Double-click on ‘Documentation’. You will find reference manuals, release notes, user’s guides and getting started

manuals.

Alternatively, double-click on ‘Examples’. You will find examples and the Weld Planner Getting Started course.

The Weld Planner Getting Started Course folder includes a complete course to manage welding distortion

engineering with the shrinkage method. In chapter seven is explained how to prepare and import meshes. This is

valid as well for the local-global method.

For PAM-ASSEMBLY, you will find two tutorials, which cover the block and the cross-section method.

You have access to a complete welding distortion engineering simulation solution under one icon. You can

manipulate meshes with a professional meshing tool, choose between shrinkage and a local-global method

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Copyright © ESI GROUP

depending on your needs, and analyze results in depth with up to date post-processing. Any background information

you are looking of is included.

PRE-COMPUTED EXAMPLES

All software components of The Welding Simulation Solution are delivered with pre-computed examples. Many more

examples are included in the engineering guide and in the training courses, as well as in the tutorials. The present

examples cover all practical situations.

MORE ON POST PROCESSING

VISUAL VIEWER STARTING FROM V5.5

VISUAL VIEWER starting from 5.5 has been completely overhauled to provide post-processing dedicated to welding and

heat treatment.

In the context bar, you can switch between Welding and Heat Treatment, Explicit, and Implicit. If you switch to

Welding and Heat Treatment, you will find a graphic user interface, which is as much as possible simplified. It offers

only the functionality that is needed.

Context bar

The following result options are gathered in one icon box:

Animation Control

Contour

Section Cut

Iso Surfaces and Lines

Model Synchronization

Model Difference

Result options

The GUI looks as follows.

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Copyright © ESI GROUP

VISUAL VIEWER 5.5 Graphic User Interface

Just double-click on the spectrum or a title – the control will pop up.

Activation of controls with a double-click ‘Animate’ the evolution of results on demand

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Copyright © ESI GROUP

Animation of results with animation control

Compare two model variants, synchronize the display, show the differences in a new window and animate it step by

step.

Distortion comparison of model variants (the difference of the two models is at the right side) and animation

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Copyright © ESI GROUP

Generate a cross section and move it through the model, with many display options.

Phase proportions in a cross section

Load a result file, display different result types, synchronize the display windows and animate the evolution of results

step by step, with individual scaling.

Temperature, stresses, distortion and plastic strains synchronized and animated

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Copyright © ESI GROUP

Display the evolution of results with graphs.

Evolution of the temperature at a node

GETTING MORE INFORMATION

RELEASE NOTES

The release notes are included in the DVD’s.

HIGHLIGHTS OF THE PRESENT RELEASE

Ask your local dealer for this document. It illustrates the highlights of the new release.

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Copyright © ESI GROUP

THE WELDING SIMULATION SOLUTION – INFORMATION FOR RESEARCH & DEVELOPMENT

Ask your local dealer for the 130 page document with all the details.


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