SYSWELD Engineering SimulationSolution for Heat Treatment,

Welding and Welding Assembly

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SYSWELD in the Virtual Try-Out SpaceSimulation is the best approach to master design, manufacturing process and in-service problemsat the earliest product stage possible.

Resulting from more than 20 years of development, SYSWELD is the leading tool for the simulationof heat treatment, welding and welding assembly processes, taking into account all aspects of materialbehavior, design and process.

Looking behind the complex physics embedded inHeat Treatment, Welding and Welding AssemblyLooking behind the complex physics embedded inHeat Treatment, Welding and Welding Assembly

MECHANICAL ANALYSIS

ELECTROMAGNETISM

DIFFUSION-PRECIPITATION

THERMAL ANALYSISMETALLURGY

Welding

Heat Treatment

SYSWELD Meets Industrial Needs

Finding out the process window:Where is the optimum ?

SYSWELD is a powerful toolthat guides engineers to find

out the optimum processparameters with respect to

distortions, residual stressesand plastic strains.

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Key success factors in the welding industry focus oneliminating as much as possible the distortions of structuralassemblies and component repair, as well as addressingdurability problems related to welding processes. Engineersinvolved in welding try to find the optimum betweendistortions, residual stresses and plastic strains by fullyoptimizing the process type and the process parameters,bringing understanding of their influence of the part shapeand the resultant material behavior.

Process feasibility,A minimum amount of distortions,A high resistance of contacting surfaces against wear,A specific microstructure fitting to the in-service purpose,A dedicated distribution of residual stresses.

By deliberate manipulation of the chemical and metallurgicalstructure of a component, mechanical properties such ashardness, yield stress and tensile stress are selectivelycontrolled.

Distortions can be minimized and forming of cracks can bedetected and avoided.

SYSWELD enables the coupled modelingof complex physical phenomena such

as electromagnetism, heat transfer, diffusionand precipitations of chemical elements,

phase transformations and mechanics.

Low distortions due to a specificpart clamping

Distortions of a crankshaft after quenching

Compressive stresses on the rollingsurface of a train wheel

Residual plastic strains

Level

Not clamped Fully clampedDEGREE OF CLAMPING

Risks of process failureLarge distortions

Risks of in service failureHigh plastic strains

Is the manufacturing process feasible ?How long will the part last ?Which tolerances have to be achieved ?How can design flaws be avoided ?

Taking into account the typical engineering questions

Heat treatment is an indispensable step inthe manufacturing of metallic products,especially in the automotive industry and inaerospace engineering. Critical successfactors in the heat treatment market focus onsafe processes, minimizing part distortionsand improving durability. Engineers involvedin heat treatment are looking for:

Distortions Plastic

strain

s

SYSWELD, the Driving Force for WeldingSimulation Technology, from Process...

Empowered by the Advisor technology, an automatic solver, and a multi-physics post-processor, SYSWELD takes into account multiple factors such as:

Process parameters,Part geometry,Thermal, metallurgical and mechanical material behavior.

SYSWELD features a comprehensive material database that covers the major steels andaluminum alloys in the market.

SYSWELD guides engineers to:

Evaluate residual distortions

Assembling a structure requires sequential continuous and/or spot welding joints.Therefore, defining the welding sequence and the places where the parts will bewelded is crucial for the correct completion of the welding assembly process.Simulation allows prediction and minimization of distortions which generate anincrease of the overall product quality as well as drastic cost saving.

Minimize residual stresses

Simulating the welding process aims to control the process in a way that minimizesthe stress gradient and tensile surface stresses. As a result, lifetime of a partincreases as fewer cracks appear after load cycles. Compressive stresses can also bedetected on the surface of the component, therefore improving part quality andavoiding corrosion risks due to tensile stresses.

Study the sensitivity of geometry, material and process parameters

Used in the design phases, SYSWELD decreases costly design errors. At each step ofthe development cycle, the cost of corrections gradually increases. SYSWELD helpsto optimize part geometry, materials and process parameters during the early stagesof a new design cycle avoiding expensive engineering changes that could occur later.

Optimize the welding process

SYSWELD allows user-defined weld sequencing and control of the weldmanufacturing parameters such as velocity, energy input and many others.

SYSWELD answers engineers’ questions

SYSWELD simulates all major Welding processes

Continuous welding• Laser,• MIG,• Electron-beam,• ...

“The challenge in the nuclear industry is to increase the life span of components.Welding repairs are categorized using SYSWELD on many different kinds of defects.”

Resistance and Spot welding

“Spot welding is very common in the automobile industry. With the coupling betweenelectromagnetism, heat transfer, metallurgy and mechanics, this process is accuratelysimulated with SYSWELD.”

Temperature field

Materialtransformations

Distortions

Residual plastic strains

Residual yield stressdistribution

Stresses due towelding and

in-service loading

Continuous welding of amotorcycle rim

SYSWELD, the complete solutionfor handling virtual welding

AUTOMOTIVE INDUSTRYWelded Assemblies

... to Application

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Space Frame Welding

Courtesy: Audi

SHIPBUILDING INDUSTRYWelded Assemblies NUCLEAR INDUSTRY

Weld Repair

HEAVY INDUSTRYMultilayer Welding

Courtesy: Vitkovize

Courtesy: BMW

Courtesy: Institut de Soudure

Meshing capabilities and group concept

Cost-effective, SY

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engineers with lim

in FEM technology

optimize heat trea

and welding assem

Compared to a tria

approach, SYSWE

solution to reduce

time. Therefore it

drastic minimizati

prototypes, leadin

a high return on in

Native CAD model of a crankshaftSYSWELD/GEOMESH providesengineers with powerful algorithms forthe generation of FE models. Patchindependent surface meshes and fullyautomatic volume meshing(hexahedrons, tetrahedrons) is availablefor welding and heat treatment analysis.The group concept allows simple andcomplete interfacing to any existingmeshing tool, and so the definitionphase of the numerical problem isextremely short and simple.

SYSWELD

Hexahedral mesh of a crankshaft. dedicated to heat treatment analythe thickness.

SYSWELD/GEOMESHCAD DATA IMPORT/EXPORT

ComprehensiveMaterial database

SYSWELD advisorsworking the engineering way

SYSWELD features a comprehensive materialdatabase. The thermal, mechanical andmetallurgical material properties are quitecomplex and depend on temperature andphases. Included are major steels, aluminumalloys and gray iron.

SYSWELD/GEOMESH provides graphicalmodeling capabilities for manipulatingFE meshes. Native CAD data isimported, automatically cleaned andprepared for FEM analysis.

The advisor technology radically reduces the time needed to set up computations for heat treatment,welding and welding assembly simulations. SYSWELD offers a fully intuitive process-drivenmethodology to set up simulations through three types of advisor:

Heat treatment advisor,Welding advisor,Assembly advisor.

YSWELD benefits

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Heat transfercoefficient wizard

Straightforward and simple workflow, from the definition ofthe project to the start of the computation

Multiphysics Post-Processor

The multiphysics post-processing capabilitiesprovide instantaneous process information forthe evolution of:

Automatic solver

The SYSWELD solver provides an automaticsolution for welding and heat treatmentproblems, covering all related complexmathematics and material physics. Dependingon temperature, phases and proportion ofchemical elements, thermal and mechanicalproperties are computed including phasetransformations enthalpy, melting andsolidification of material, large strains,plasticity and transformation plasticity.

Temperature field,

Heating and cooling

rates,

Metallurgical

structure of the

material,

Distortions,

Stresses,

Yield stress of the

modified material,

Plastic strains.

Contour plots,

Iso-lines and Iso-

surfaces

Vector-Display,

x-y diagrams,

Symbol plots,

Numerical

representation,

Cutting planes,

Animations.

Result analysis SYSWELD provides a variety of techniquesfor reviewing process results including:

in Action

Compressive stresses displayed on the distorted structure

The layered mesh generator issis from the surface and through

Graphical user interface:efficiency, flexibility

The interface comprises engineering tools to adjust allnecessary process parameters and a straightforward andsimple workflow, as part of the heat treatment, welding andassembly advisors. S

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SYSWELD, the Driving force for Heat TreatmentSimulation Technology, from Process...

SYSWELD computes and optimizes all basicsteps of the heat treatment process:

Austenitization for surface hardeningAustenitization for through hardeningQuenching, austempering, martempering and tempering

SYSWELD simulates the following processes:Surface hardening

• Induction • Laser• Electron beam • ...

Through hardening• Direct • Austempering• Martempering • ...

Thermo-chemical heat treatment• Carburizing • Nitriding• Carbonitriding • ...

Tempering

From the start of the software to the start of the computation it usually takes 30 minutes or less,including Finite Element modeling. Even 3D computations of distortions and residual stresses areperformed in less then one day. As a consequence, answers are provided more efficiently to thebasic questions from heat treaters and designers:

Is the selected heat treatment process feasible ?Is the selected steel feasible ?Is the selected quenching media suitable ?Is the process window safe against process tolerances ?Is the part hard where it should be hard ?Is there any crack risk occurring during the process ?Are the obtained distortions acceptable ?Are the residual compressive stresses high enough and well positioned ?

The heat treatment product solution is especially suited for heat treatment job shops,which need to ensure the feasibility of a heat treatment process within one day.

SYSWELD answers engineers’ questions

Through hardening ofa train wheel

Temperaturefield

Phasetransformations

Distortions

Residualyield

stressdistribution

Residualplasticstrains

Residualcompressive

stresses

SYSWELD, the complete solutionfor handling heat treatment technology

SYSWELD simulates all majorheat treatment processes

Typical CCT diagram

SYSWELD performs simulations taking into account all physical phenomena involved in the heattreatment process. It provides extended databases for materials – phases and temperaturedependent - and quenching media. The numerical methods implemented are highly optimized forthe computation of heat treatment processes.Specific technical capabilities are provided for the Finite Element modeling of the heat treatedstructure. The requested high quality in computed results requires a refined layered mesh from thesurface through a few millimeters of thickness of the part. For 2 dimensional structures, a guidedlayered mesh generator is available. For 3 dimensional structures, a fully automatic layeredhexahedral mesh generator is accessible for solid parts of any complexity. As a result, SYSWELDdrastically reduces the time to mesh parts while offering high quality Finite Element models.

... to Application

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Cooling rates over temperature in theCCT-diagram, for any critical point of the structure.

Case hardening of gears

Comparison of gear distortionswith various carbon enrichments

Courtesy: EFD Induction Group

Ferrite/Perlite

Martensite

Bainite

Cooling rates are too low to give martensiteat a critical point of the structure.

Judgement of process feasibility andstability against process tolerance

Surface heat treatmentof a crankshaft

Tem

pera

ture

(°C

)

Cooling rates (°C/s)

Heat treatment process

Courtesy: Ford

Low and high carbon content

SYSWELD in the Virtual Try-Out SpaceSYSWELD is not only a simulation tool, it is also a design optimization tool,created to help you gain competitive advantage.

Chaining SYSWELD and PAM-STAMP

Paving the way towards the digital factory

Chaining stamping and welding simulation

ESI Group’s value chain for Virtual Manufacturing productsincludes PAM-STAMP, the integrated stamping solution to masterthe complete manufacturing chain from die design feasibility tostamping validation and optimization. Chaining with SYSWELDbrings state-of-the-art manufacturing prediction.

Welding tailored blanks generates material changesaround the welding joints that influences the stamping behavior.Chaining SYSWELD and PAM-STAMP provides the user with keydata about changes in material properties like yield stressreduction. The residual stresses from welding are taken intoaccount for the spring back simulation.

Chaining PAM-STAMP and SYSWELDWelding stamped components made from aluminum and steelalloy is today the mission-critical operation for body-in-white andsuspension systems. Combining PAM-STAMP and SYSWELDbrings an accurate assessment of real blank thickness, change inmaterial, distortions, residual stresses and residual plastic strains.

Benefits:Improved products and tooling designMore accurate process simulationReduced tooling modifications

Welded joint usinglocal/global technology

BlankholderPunch

Blank

Die

Welding/Stampingcoupling of a

tailored blank

Courtesy: Audi

Companies within the heat treatment,welding and assembly markets face highpressure to reduce costs and lead times,as well as to increase part quality. Theseobjectives can be achieved by focusingon manufacturing process optimizationand part improvement. To betterrespond to industrial constraints,ESI Group pursues its continuouscollaborative development of SYSWELDand helps engineers to reduce thenumber of prototypes leading to themigration towards the digital factory.

Car manufacturers are under high

pressure to decrease weight, costs, time-

to-market and increase quality by

optimizing heat treatment and welding

processes at the earliest stage in the

design process.

A car component is manufactured from

different parts which are stamped, cast,

bent, then welded and connected

together to fit the welding assembly

requirement.

SYSWELD is the ideal simulation tool for

improving the welding and welding

assembly processes, ensuring better part

quality.

It provides realistic input data for

subsequent structural behavior, durability

and crash analyses. It is a unique

engineering solution tool, which can lead

to unsurpassed productivity gain.

SYSWELD Masters Joining Technology

References and partnerships

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Arcelor, Audi, BMW, Bechtel Bettis, Bosch, Corus,DaimlerChrysler, Delphi, EADS, Ford, Framatome, FujiElectric, GKN, GM, Hawtal Whiting, Hyundai Heavy Industry,Japeic, Knolls Atomic Power, Korean Heavy Industries, Mitsui

Babcock Energy Ltd, POSCO, PSA Peugeot-Citröen,QinetiQ ltd, Renault, Rolls-Royce Aerospace, SamsungHeavy Industry, SKF, Toshiba, Toyota, Vallourec, Volvo,Wagon, ZF, ...

SUPPORTED PLATFORMS:PC and Unix workstations

Simulation strategy to guaranteethe functionality

PROCESS

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ESI Group is a pioneer and world leading provider of digital

simulation software for prototyping and manufacturing

processes that take into account the physics of materials.

ESI Group has developed an entire suite of coherent, industry-oriented applications to realistically

simulate a product's behavior during testing, to fine tune the manufacturing processes in synergy with

the desired product performance, and to evaluate the environment's impact on product usage.

ESI Group's product portfolio, which has been industrially validated and combined in multi-trade value

chains, represents a unique collaborative, virtual engineering solution, known as the Virtual Try-Out

Space (VTOS), enabling a continuous improvement on the virtual prototype. By drastically reducing

costs and development lead times, VTOS solutions offer major competitive advantages by progressively

eliminating the need for physical prototypes.

PAM-SYSTEM and all PAM-product names are trademarks of ESI Group - All other trademarks are the property of their respective owners - Specifications are subject to change without notice.

AGENT:

About ESI Group

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