How to Simulate the Arc Welding Process in Simufact with an Example

Summary

This video tutorial, presented by Muhammad Amin Kanjabi and narrated by Neelu Fireskandari from Hyperlysium, guides users through the basic usage of Simufact Welding GUI and simulating arc welding processes. It covers model configuration, material properties, geometry generation, clamping, welding parameters, and solver setup. After setting up the simulation, users learn how to execute it, monitor progress, and perform post-processing to analyze stress, temperature, and other results. The video also provides instructions on extracting results and encourages viewers to reach out with questions via email or through the Hyperlysium site.

Takeaways

• 😀 Learn the basics of using the Simufact Welding GUI and simulation of arc welding processes.
• 😀 The initial setup screen allows configuration of components like clamps, robots, and other settings.
• 😀 Ambient temperature, gravity direction, and boundary conditions can be defined and adjusted later in the process.
• 😀 The simulation allows you to define the number of components, including robots and bearings, and adjust model settings.
• 😀 Importing a mesh in BDF format is essential for the project; files can also be downloaded for free from the website.
• 😀 Material properties can be set by selecting materials from the library (e.g., STK M13A for components, G2SI for filler material).
• 😀 The geometry for bearings and clamps can be generated and adjusted, such as modifying dimensions and positions.
• 😀 Welding parameters, including heat source settings (velocity, current, voltage), are defined for the simulation.
• 😀 The simulation requires configuration of robots and trajectories for welding, including fill geometry and robot movement.
• 😀 Post-processing allows users to analyze results such as temperature, stress, and strain, and generate relevant diagrams.
• 😀 Users can extract results like stress and strain values to assess the impact of the welding process on the model.

Q & A

What is the main purpose of the video?

The video aims to teach the basic usage of the Simufact Welding GUI and demonstrate how to simulate arc welding processes.

What settings can be configured initially when setting up the model?

You can specify the number of components, bearing clamps, robots, and other settings. Additionally, you can define the ambient temperature, direction of gravity, and pre-select boundary conditions.

Can the initial settings be changed after the model is configured?

Yes, all the initial settings can be modified later, so you can add more features or change parameters as needed.

What is the purpose of selecting the ambient temperature and gravity direction in the setup?

The ambient temperature defines a global value applied to the whole model, while the gravity direction specifies how gravity affects the model during simulation.

How are the mesh files imported into the Simufact Welding software?

Mesh files are imported by right-clicking on the geometry, selecting the library option, and choosing the appropriate plate and tube files from the directory. You can also download them from the website for free for a limited time.

What is the significance of defining material properties in the model?

Defining material properties is crucial to ensure that the simulation accurately reflects how the components will behave under welding conditions. The material properties are selected from the library and assigned to specific components (e.g., using STK M13A for components and G2Si for filler material).

How do you define the geometry of the bearing in the model?

The geometry of the bearing is defined by right-clicking on 'bearing', selecting 'generate geometry', and choosing the type as cuboid. Specific dimensions and positions are then entered for width, height, depth, and direction.

What are the steps involved in defining clamping in the model?

To define clamping, you first generate the geometry of the clamping, select the type as a cylinder, modify the location and radius, and apply the stiffness and force values for the clamping components.

How is the welding heat source defined in the simulation?

The welding heat source is defined by setting parameters such as velocity, current, voltage, and efficiency in the 'welding parameters' section. These values help simulate the heat input from the welding process.

What steps are taken to run the simulation in Simufact Welding?

To run the simulation, the model is first fully configured, then the scope icon is clicked to open the Simufact monitor. Afterward, the green arrow is clicked in the analysis control toolbar to start the simulation.

What is the role of post-processing in this simulation?

Post-processing allows you to analyze and extract results from the simulation, such as temperature, stress, pressure, and error percentage. The results can be visualized through graphs and diagrams, and further details can be extracted as needed.

How are results extracted from the simulation, such as stress or strain?

To extract results, you select the relevant option (e.g., stress or strain), choose the desired chart type, and then follow a procedure to view and export the data, depending on the needs of the project.

Can the model configuration and simulation results be modified after execution?

While the model configuration can be modified before execution, the post-processing results are available for analysis after the simulation is completed, allowing for adjustments and further interpretation of the results.

Who should be contacted for further assistance with the project or software?

For further assistance, you can contact Muhammad Amin via email or visit the Hyperlysium website. The video also provides contact information for project discussions and online sessions.