scholarly journals Robustness and sensitivity analysis of a virtual process chain using the S-rail specimen applying random fields

2016 ◽  
Vol 734 ◽  
pp. 032126
Author(s):  
T. Konrad ◽  
S. Wolff ◽  
K. Wiegand ◽  
M. Merklein
Keyword(s):  
Sensitivity Analysis ◽  
Random Fields ◽  
Process Chain ◽  
Robustness And Sensitivity Analysis ◽  
Virtual Process

Tolerances and Measuring Strategies in the Virtual Process Chain for Spot Welded Structures; Substitute Modeling and Automating the Calibration Procedure

2015 ◽  
Vol 794 ◽  
pp. 3-10
Author(s):  
Patrick Ackert ◽  
Christian Schwarz ◽  
Reinhard Mauermann ◽  
Dirk Landgrebe
Keyword(s):  
Spot Welding ◽  
Computing Time ◽  
Numerical Procedure ◽  
Calibration Procedure ◽  
Welding Distortion ◽  
Process Chain ◽  
Welded Structures ◽  
Body Construction ◽  
Calibration Samples ◽  
Virtual Process

This paper presents a method with whose help it is possible, to quickly and precisely predict the influence that thermal spot-shaped joining processes has on the dimensional stability of complex component structures even in early planning phase. The welding distortion is calculated in the context of reduced computing time, based upon an experimentally calibrated mechanical substitute model. This expands existing approaches of substitute models and defines both an experimental and numerical procedure for creating adequate calibration samples. In turn, this makes use of the potential obt ained for standardizing the experimental basis for calculating and modelling the distortion to automatically carry out painstaking calibration processes in simulations and experiments in future based upon mathematical model functions. Finally, the limits to applying the substitute spot welding model are verified with reference to its predictability using a complex joining situation of a car body construction.

Recent Developments in LS-DYNA to close the Virtual Process Chain for Forming, Press Hardening and Welding

2015 ◽  
Vol 651-653 ◽  
pp. 1312-1318 ◽  
Author(s):  
Thomas Klöppel ◽  
Andrea Erhart ◽  
André Haufe ◽  
Tobias Loose
Keyword(s):  
Material Properties ◽  
Manufacturing Industry ◽  
Plastic Material ◽  
Base Material ◽  
Process Chain ◽  
Press Hardening ◽  
Multistage Processes ◽  
Recent Developments ◽  
Material Formulation ◽  
Virtual Process

Forming, press hardening and welding are a well-established production processes in manufacturing industry, but predicting the finished geometry and the final material properties of the processed parts is still a major issue. In particular, deformations caused by welding are often neglected in the virtual process chain, although they have to be compensated for in order to fulfill the requirements on shape tolerance. This presentation will give an overview on novel features of LS-DYNA implemented particularly for welding simulations.To begin with, new keywords will be presented that allow applying the heat generated by the weld torch. LS-DYNA offers a very convenient way to define the well-known Goldak heat source, but it is also possible to define arbitrarily shaped torch geometries.In order to obtain a predictive model for welding simulations, specific material models have been devised in LS-DYNA. The properties of filler material in weld seams are accounted for by a ghost material approach. Material is initialized as ghost material and is activated, i.e. it is given base material properties, when the temperature reaches the melting point. This approach has been implemented for a relatively simple thermo-elasto-plastic material formulation *MAT_CWM as well as for the more complex material law *MAT_UHS_STEEL. The latter has initially been implemented for press hardening simulations and is able to predict the microstructure of steel alloys including phase transformations and the resulting mechanical properties.In this contribution, details of the material formulations and novel features are presented. Examples will demonstrate how these features can be applied to multistage processes including several forming and welding stages.

scholarly journals Design of Hybrid Components Joining Zone through Sensitivity Analysis

2019 ◽  
Vol 1 (1) ◽  
pp. 2697-2704
Author(s):  
Renan Siqueira ◽  
Sean Shugar ◽  
Iryna Mozgova ◽  
Roland Lachmayer
Keyword(s):  
Sensitivity Analysis ◽  
Design Method ◽  
Design Guidelines ◽  
Process Chain ◽  
Parametric Sensitivity ◽  
Application Potential ◽  
New Challenges ◽  
Manufacturing Technologies ◽  
Tailored Forming ◽  
High Application

AbstractMulti-material structures are a trending topic for the industry. With a high application potential, such as lightweight or extended life cycle, different manufacturing technologies are further developed for this intent. One of these technologies is Tailored Forming, a process-chain capable of joining different metals and creating massive hybrid components. In parallel to this development, new challenges rise for design, which has the responsibility of finding an optimal use of this technology and produce higher- performance products. However, this task cannot be solved by conventional engineering approach, since strong manufacturing constraints are involved and a lack of understanding about the joining zone formed between the materials still exists. To fill this gap, the objective of this study is to analyse the influence of the joining zone design over the structure behaviour and establish a suitable design method. For that, a computer-aided environment was constructed and a parametric sensitivity analysis was executed, taking a hybrid shaft as example. At the end, the simulation's results allowed a multi-objective optimisation and were able to generate first design guidelines.

An Integrated Virtual Tool Chain for the Simulation of the Manufacturing Process of a Composite Tidal Blade

2017 ◽  
Vol 742 ◽  
pp. 705-713
Author(s):  
Christian Brauner ◽  
Frédéric Pascon ◽  
Tom van Eekelen ◽  
Maarten Bach ◽  
Arjen Kolovaar ◽  
...  
Keyword(s):  
Manufacturing Process ◽  
Structural Model ◽  
Data Communication ◽  
Complete Analysis ◽  
Simulation Methods ◽  
Process Chain ◽  
Tool Chain ◽  
Mapping Algorithm ◽  
Direct Data ◽  
Virtual Process

Within the European research project ECOMISE advanced process simulation methods have been developed. Existing Software tools like RTMWorx and NX CAE have been extended in their capabilities and interface have been developed between them to have a direct data communication. In the present case a manufacturing process of a tidal blade was used to test and validate the development. In RTMWorx a new 3D solution was developed and an a import interface to read direct a structural model from NX with all related information’s like geometry, mesh and layup. The interface reads the ply information’s and calculates resulting permabilities for the layup. In NX CAE also interfaces and mapping algorithm have been developed to read information’s like filling factors from RTMWorx. In combination with the new functionalities to simulate curing, process induced deformation and residual stresses the virtual process chain enabling a complete analysis of the whole manufacturing process starting from a initial design with capabilities on draping including direct ply contour creation, infusion, curing and analysis of process induced deformation.

Virtual process chain for optimization of sandwich foldcores under flatwise compression

2020 ◽  
Vol 157 ◽  
pp. 107121
Author(s):  
Fabian Muhs ◽  
Simon Thissen ◽  
Peter Middendorf
Keyword(s):  
Process Chain ◽  
Virtual Process
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