Tutorial for Visual Environment 777

8/8/2019 Tutorial for Visual Environment 777

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Tutorial for Visual Environment 6.5

ESI Group software

By

Angjele Ivanovski

ISAF – TU ClausthalPure Inspiration ®

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Table of contexts :

Introduction


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Introduction :

Visual Environment is union of programs that help modeling,

simulate and test a lot of mechanical process that industry uses

today and were used before. In this tutorial we will focus on the

Welding process and the benefits of welding simulation. The first

step is making the model with sub program Visual MESH. In this

Sub program you will draw our model, give its geometrical shape

and define the welding path, the surface impact by the heat, the

cooling surface, clamp conditions and much more, as you can see

later. After the preparation of our model in Visual MESH we start

our second sub program Visual Weld. In this program we will put

our welding conditions such as Material that is going to be weld,

Welding speed, energy, cooling conditions and etc. This program

will generate most of our post processing file separating them onHeat Treatment and Mechanical Treatment. To have a final view of

the results we will start our last program Visual VIEWER where we

can see the hole process and how our model react to the heat

treatment and the influence of the clamped conditions as one of

the many mechanical characteristics of the welded material. In

this Sub program we can create an plot and save it as Image or

we can make an video so that we can have good presentation of

our model.


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For easy working and quick learning of this program we will need to know some

basic of drawing and modeling, it’s in our best interest also to read any material

that shows us what we need to know about FEM simulation solutions and tests

and in our high priority is to read and practice more about making the mesh as

close to perfection as it could be.

At the next picture we can see the welcome screen our first start point. Take your

coffee and your positive energy let’s start.


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Step by step through the menu:

Aplications : in this menu we can switch between our sub programs : Visual

MESH, Visual WELD and Visual Viewer.

File : is normal menu where you

open new document, save export and

etc.


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Edit: also is common used menu with the copy,

paste, select and etc.

View: is the menu where you set up

your point of view, Compass option,

change the background color of thewindow and etc.


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Curve: The menu from where we start

our drawing contains: Sketch choice

which we can use for drawing straight

and curve lines, Circle and arc fordrawing of rounded models, trim\split

for cutting, transform for changing the

position of the model or making a copy

out of it and etc.

Surface: this menu can show us the

option where you can create a surface

and edit it.

We will take some time to have a look at the menus


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For our easy learn tutorial we will weld a 200 x 200 x 2mm Steel Probe.

Our material is DP 600 and the welding process is MAG.

We click on the File menu and select New. As we can see the background

of our working space has changed the color.


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On the left corner of the working space you can find the 3D coordinate

system. While clicking on the circle you can modify the coordinate system

as is your wish. Now we will have to start drawing in 2D coordinate

system, click with the mouse under the surface menu and chose one of

the given 2D coordinate systems.

We will select XY for our start system so that our

extension could be in Z axis.

It is important to safe as much times as you can

and maybe by different names just to have back

up of your last work.


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for our further work is important the files to be saved in one folder, click

on file menu choose save, pick desktop for start and create there an folder

in this example we will call the folder “saved files”, the model name would

be “TEST1” the extension of the file is .vdb it’s the program default and for

our work is the best it saves most of the data used and Visual Weld uses itfor further processing ex. Heat and mechanical.

Now we are at the start line, what we see in front of us it’s a program that

can offer much but here

we will learn about the

basic and I hope it

motivates you to learn as

much as you can from this

program because it has a

wide range of uses.

It’s important to have a

visual in your head or even

more drawn on paper of

what your probe looks like.

The proper dimensions are

priority for better and

better results.


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Now select the Sketch menu and chose Curve, a small window pop up in

the left corner, take the mouse and drag near the coordinate start.

Select the Linear option, and with the

mouse click on two random points at the

background screen.

Note * the pictures from now on would be in white background so that

when we make a print we don’t use much color. You can change the

background workspace color following this step’s: click on View menu and

from there you choose Window Background color and you select what you

mostly like.

After we click two random points, we would like to edit them so that we

can get in the dimensions that we want. Go with the mouse and click on

the red point that it’s close to the coordinate system, a new window is

open here first select the axis that you would like to edit and then delete

the previous number and write the one you need for our example its 0 (x)


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0 (y) and 0 (z), after that press enter or press the axis button in the point

definition window.

The same we will do for our second point over there we will put number

100(x), 0(y), 0(z). While clicking next to the point, not on the point you will

draw a third point. That is what we don’t like for this example so just click

undo on the Sketch Curve Window.

Now it’s ok so we must click Apply if we don’t like this to happen again.

You can click on the Apply button inside the Sketch Curve menu or the

small box with orange ‘enter’ sign. When you click apply the line cannot

be changed any more. Now click on other two random points on the

background. First select the point that it’s close to our last point. We have

two ways to connect them one it’s that we manually write down the


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coordinates or we click End of Curve Button that’s inside Point Definition

window. Either of the ways will take us to our result. On the other point we

would put 100(x) 100 (y) 0 (z). Click Apply our line goes out of the

window?!?!?! Its easy we can get it back : scrolling the middle mouse

wheel forward to undo zoom or to get a bigger view, scroll it backwards

you will get zoom in, if you don’t have mouse wheel you click on the

keyboard strg(ctrl)+ F this is command for fit to window.

Now we will use the same procedure for the two edges, after we click for

the creation of two new random points, one point of the horizontal line

would be End of Curve, the other one would have this coordinates 0(x),

100(y),0(z). The last vertical curve is also created by two random points,

but here

we click

End of

Curve


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for both of them selecting it in order to get a square shape connected

curves.

Don’t forget to save as many times you feel it’s necessary. We should

save the probes with names in other to remember our work step by step so if we


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make mistake in the next step or our pc makes us problem we would have a

good back up.

Now we have curves but not a surface, we have to create surface

following this steps: Click on the surface menu and select sweep drag. The

following new window appears. Click on the vector button select globalaxis and in the “Along” box choose X Axis.

After we select what we what it is shown in the orange circle in the pictureabove we Click OK to continue.

After that click on the button Points marked with light

green circle shown on the picture that it is on the previous

page. Then click on two vertical points away from the

square but close to his surroundings. You will get this

yellow line click on the middle wheel mouse button and

we will get Orange Square who is located outside of ourcurve square. To create a surface out of curves we have

to change the distance so in the distance box we put 200

just to be sure that all of our curves are inside the created

box.


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“Before “


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“After“

To make sure that we have made surface we can change our view point

for a second of time.

Go with the mouse below Edit and View

menu see some gray color small squares

click on the one Smooth. See the

pictures below the curves are covert with

green surface.


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Click on Edge the first square from left to right to get back in previous

point of view.

Now we have to separate our curve square from the surface square, for

that we would use command Split from the Surface menu.


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There is a new window, down the left corner of the program. We will click

on the Surface menu and select the Surface button and we click between

our curved drawn surface and our created surface. Then click on the

middle mouse. After that we shall click in the small menu “Split by “we

choose Curves and we select the curves that we draw manually. When weselect them step by step we can notice that they are turning yellow. After

selecting them we press middle wheel of the mouse. We can notice that

the color of our bigger surface has change this shows that we are on a

good way click apply and its finished.

To make sure that we have created two surfaces we go on the falling down

menu on the left side.

We don’t need the bigger surface so, we

click on

the space

between

them.

Can we

see the

yellow

transformation of the lines of the bigger surface and the lines that go

around the drawn surface? If we can that means that we have made good

choose, press delete ( Einfg) and the bigger surface would be gone.

This is too big, now we have to make a smaller section of our plate. Let’s

divide on three smaller parts. To do that we have to draw two more curves

Let it be for our example the curves have coordinate 20mm and 50 mm.


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Our first curve will be 20 x 0 y and 20 x 100 y

second curve will be 50 x 0 y and 50 x 100 y .

We select Sketch menu and we click on Curve the procedure is the same

after we finish we should get this.

after we click apply and we close the window we have to split this

surfaces, select Surface form the up menu and click on Split . For selection

of surface you select the square surface and under curves you select the

two new drawn curves. Click on the middle button of the mouse and then

apply.


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Now its good point to save the work you have done so this save could be

saves as TEST1surface.vdb.

If we like to make welding we must put net on our probe, net alsoknown as mesh. Maybe at the start we would find some problems

during the mesh but don’t worry with practice it will get better

and better.

To activate the mesh window we select the 2D menu and click on the Auto

mesh Surfaces.

Now select the smallest surface or the first from right to left, because here

we like to put the welding we would have to give this surface more

detailed mesh. Soon as you clicked on the surface, click on the Createmesh button in the Auto mesh window.

The new window appears and there is auto generated mesh that it’s too

big for our probe. That why we change the number in the Element size boxfrom 10 to 2 and we click on Create mesh button that is down in the right


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corner of 2d mesh window.

Now we click on the ok and we can continue with the second surface but

lets make it bigger now. After we click on the surface and then click on

create mesh then we this time put 3 For ELEMENT SIZE, and click on

Advanced in the small option menu and sign on the box within part. * you

can see on the picture below! After that you will click on method in thesmall option menu, in Element options under type put :Quad – Tria , and

under Order : Quadric. For Method choose MAP. This may not look like a

good mesh but for this tutorial its ok, the mesh would get better with

experience and strongly depends on the welding process and on what you

would like to get out from your simulation.


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After you do this click on create mesh, we have the final the biggest

surface.

We select it and we click on Create Mesh, because this part we would try

something different just to show the wide selection of opportunities that

this program can offer. Now we are at the first page of 2D mesh menu, inthe Edge Section under Biasing at Type section we put exponential we

choose factor 3. We click on Bias edge and we select the horizontal edges.

Oh no one of our edge its flip on the other side choose Flip the first box

before the Bias Edge and correct the edge in order from smaller start to

bigger size ending. Hmm this is not ok our first section of elements its

smaller than our last section from the second part… that’s not a

characteristic of a good mesh.


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So we would like to change things at the last box with name Count we

enter 10 and we click on set to edge button then we select the horizontal

edges of our third part. To be sure after the click on one of the edges we

will click the edge button again and click on the other Edge. Click Create

mesh and ok now we are Finished with the mesh. To view the part better

click on the Flat and wireframe button under view and edit on the top

menu.


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This is one half of our probe, we

would have to copy to get the other

half. To do this we would use the

transform command from Surface

menu, it is the second command

from down to up.

When you open the transform

window you have to click on Mirror

option and from mirror select copyoption, now you have to chose the

plane, set it to global and choose X

axis.

Click on Element, there is a menu that

falls down, from it choose Element

before 2D options, and after that click

again and Choose Sell ALL button.

After clicking on the green enter sign

next to the Element button, you will


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get half blue half yellow surface, click on Copy button at the end and you

will get the probe in right shape.


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During the transformation some of the nodes are not connected so we

click on the Checks menu and we select the Coincident Nodes option. On

the Coincident Node window we have lot of options but first we have to

press Check under Validate opinion and take a look the Max Gap is 0.1.

This option can be changed that one depends on our next tests.

For this example its good.

The picture on our screen changes,

now click on Node in Fuse Nodes

option and click on Fuse all. Now we

have connected all of the missing

links between elements we can go

to making 3D model.

In the 3D menu choose sweep drag

option, in the small window that pop out

we must select this opinion look at the pic.


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From the vector window we would

select the z axis as our main extrude

axis. And for distance we choose 2

because the probe has 2 mm

thickness.

After this we click on Element face and from the menu above we choose

the option select all


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I have clicked mirror option more than once so I had two layers of 2d

objects I am sorry. ****

When we will finish with the 3d window, and the swap window, to have a

better look at the probe let’s try on the flat and the wireframe square.

Now we have to delete the previous made 2d plate and renumber.

Select 2d from elements, under geometry at the left side menu. Make a

right click and delete.


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On the top menu under Assembly click on the Advanced Renumber and on

the new window select all Elements, nodes and parts. Click on the

renumber button and close.

Now we have to start creating the components that are important for the

visual welding.


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Click on the 2D menu and choose extract from 3D .

On the new window we click on the

element face and then from the top

menu we click on select all button.

When all of the elements are in yellow

color click on the extract button. Wecan easy see the change in the menu

on the left side.


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Now we have to make the collectors.

On the left sided menu click on 2d elements with right click and choose

LOCATE, after this click on select all button from the top menu. Since all of

the elements have turned yellow on the background click the right mouse

button and in the tools option click add new collector.

In the left side menu we can notice that

there is a new object added. Click on it with

the right mouse button and press edit This

collector we would name itSOLID_AIR_HEAT_EXCHANGE.


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Now we have to make the

same procedure for our

next collector.

Component_1 but this

collector we would take out

from the 3d surface. On the

left side menu we click on

the 3D Element with theright mouse button and we

press Locate. After we

press locate from the top

menu we press the select

all button. Soon as our

probe turns yellow we click

on the background with

right mouse button and we

select add new collectorfrom tools menu.

After we see the new component on the left menu we edit its name in

COMPONENT_1

With this component now we have the welded probe and we have the way

of getting the heat out of material, now we have to focus of the heateffected zone or in our case cold LOAD. On the left side menu we click on

the 3D elements and locate while our point of view its set on Flat and

Wairframe we click on 10 shells in line left rom the centar of the probe

and 10 shells in line that are on the right. If you like you can select all

depends on your choise. When we select 20 shels in line we select all

shells that are in our path starting form top to bottom fo the plane. After

we select them we check if everything is ok and then we click on the


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background with right click and we flow the same procedure only naming

this probe LOAD_1.

Now we have to select clamp nodes.

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Tutorial for Visual Environment 777

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