ESI Group
10
New Release of the Welding
Simulation Suite
Distortion Engineering V2010 / Sysweld V2010 /
Visual Environment V6.5
The ESI Weld Team
2 | P a g e
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
3 | P a g e
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
4 | P a g e
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
5 | P a g e
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
6 | P a g e
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.
7 | P a g e
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.
8 | P a g e
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)
9 | P a g e
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.
10 | P a g e
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.
11 | P a g e
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.
12 | P a g e
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.
13 | P a g e
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.
14 | P a g e
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
15 | P a g e
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
16 | P a g e
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
17 | P a g e
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
18 | P a g e
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’.
19 | P a g e
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
20 | P a g e
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.
21 | P a g e
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
22 | P a g e
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
23 | P a g e
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
24 | P a g e
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.