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1. 117 SORPAS User Manual Version 10 6 Wedge definition gt Rectangle on x y plane on the screen Bulk thickness in Z 2 mm y m4 i 2 x Z a a Wedge geometry on y z plane look from right to the left 1 Angle to x axis 90 and Bottom length 0 5 mm 2 Angle to x axis 270 and Bottom length 0 5 mm fon s ahe aide H WZ Wedge geometry on x z plane look from top downward 3 Angle to x axis 0 and Bottom length 0 5 mm 4 Angle to x axis 180 and Bottom length 0 5 mm i amp osf 0 5 2011 SWANTEC Software and Engineering ApS www swantec com 118 SORPAS User Manual Version 10 6 Wedge definition Half in Z Rectangle on x y plane on the screen Bulk thickness in Z 2 mm 4 K 2 x Zz a a Wedge geometry on y z plane look from right to the left 1 Angle to x axis 90 and Bottom length 0 5 mm 2 Angle to x axis 270 and Bottom length 0 5 mm ade cie t E Wedge geometry on x z plane look from top downward 3 Angle to x axis 0 and Bottom length 0 5 mm 4 Angle to x axis 180 and Bottom length 0 5 mm 0 5 os im 2011 SWANTEC Software and Engineering ApS www swantec com 119
2. 2011 SWANTEC Software and Engineering ApS www swantec com Timm SORPAS R Version 10 1 Enterprise Edition C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved aaa Fig 36 Input window for simulation control parameters Enter the time step increment for the squeeze time the weld time and the hold time The numerical simulation is carried out incrementally with time steps The Time step increment is the length of the time step used during simulation Reducing the time step may improve accuracy of simulations regarding to dynamics especially for problems with strong dynamics of temperature development and deformation of materials etc but will consume more computation time since the number of steps for calculation is increased In the example a time step increment of 0 5 ms is used for the squeeze and 0 2 ms for the weld time while a time step increment of 1 0 ms is used for the hold time Define the frequency for saving the results during simulation The Save data per steps implies that with an interval of how many steps the results will be saved to the hard disk The saved results will be used to generate animations after simulation In order to save disk space it is not 58 SORPAS User Manual Version 10 6 4 5 necessary to save data every step especially when running simulations with a small time step increment In the example
3. A B D 5283 mm Fig 3 The report of simulation generated by SORPAS for example sl s1_Coating the upper part is the welding conditions and the lower part is the main simulation results 2011 SWANTEC Software and Engineering ApS www swantec com 21 Version 10 6 SORPAS User Manual 2 3 3 sheets dat The example 3 sheets is a simulation of three sheet spot welding with one 0 8 mm mild steel sheet one 1 5 mm HSLA steel sheet and one 1 5 mm DP600 steel sheet The electrode is type B with a tip face diameter of 6 mm This example also shows the use of multi pulses during welding The welding process parameters used for the simulation are shown in Table 4 and the report of simulation generated by SORPAS is shown in Fig 4 Table 4 Weld parameters for example 3 sheets Filename Squeeze time Weld time Hold time Current RMS Current Force type ms ms ms kA 3 pulses KN 3 pulses of 3 sheets 40 180 ms 300 11 0 AC 4 3 S O RO 3 S S2RPAS R Version 10 1 Enterprise Edition F C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved Simulated with SORPAS R Version 10 1 Simulation finished 01 03 2010 12 00 00 Filename Problem ID Materials Electrodes Report of Simulation C SORPAS 10 1 Demo Work 3 sheets dat Example 1 Design of Weld Combination Computation time Process Parameter Settings 18
4. 3 500 Max 6 500 Nominal 6 000 mm Note The weld growth curve is generated at predertermined or given constant weld time and weld force referring to 1S014327 2004 sornpas cet Fig 41 Control parameters for automated optimization of weld current according to a requested weld nugget size 2011 SWANTEC Software and Engineering ApS www swantec com 63 SORPAS User Manual Version 10 6 Prediction of the Weldability Lobe with varying weld current and time The weldability lobes show the range of two welding process parameters with reference to the required weld nugget sizes Two types of the weldability lobes as defined in ISO 14327 2004 can be predicted automatically with SORPAS The first type is the weldability lobe with varying weld current and time but constant force The parameters can be defined in the data input window as shown in Fig 42 The maximum and minimum weld current with an increment and similarly the limits of the weld time can be defined for generating the weldability lobes Three weld nugget sizes can be given as references minimum nugget diameter maximum nugget diameter and minimum nugget height penetration in the thinnest outer sheet A matrix of simulations will be prepared and run automatically with varying weld current and weld time as specified After all simulations are finished the weldability lobes will be obtained as shown in Fig 10 in Section 2 9 Define Parameters for Welda
5. AUNI ND N e N I Fig 23 Window for moving selected objects 2011 SWANTEC Software and Engineering ApS www swantec com 43 SORPAS User Manual V Vi VII VIII IX 2011 SWANTEC Software and Engineering ApS www swantec com Version 10 6 Click Size to change the width or the height of the selected objects The Sizing window is shown in Fig 24 The selected objects can be resized by directly modifying the dimensions or by a user specified percentage of sizes in one or both dimensions a Sizing width 8 0000 Height 20 0000 H imm 10 10 Select Object s Electrode Interface Workpiece Interface Workpiece Interface Electrode Tool force Tool static Water Water PWNANOO BWM Cancel soroas Fig 24 Window for sizing selected objects Click Delete to remove the highlighted object Click Merge to combine selected objects into one or fewer number of objects The Merging window is shown in Fig 25 r Merging Select Objects to Merge Electrode Coating Workpiece Coating Interface Workpiece Interface Electrode 0 w D N e a N Fig 25 Window for merging selected objects The Object Scroll Bar is used to search the objects Return to step for new object and perform the same procedure for all materials and contact interface layers 44 SORPAS
6. Machine Settings Simulation Control yg Type of Geometric Model Type of Symmetiy Line x Axisymmetric model Vertical symmety line x 0 Block model Model 1 of T symmetric division s is Ea Elements 1000 Advanced ViewMesh Generate Mesh Delete Inset Size Move Mee abiect1 J gt 2 000 2 000 7 Definition of the Current Object Electrode C Work piece C Coating C Interface Category Electrode materials z Materiak ISO 5182 A2 2 Electrode CuCiZr E ID 2 Initial T 20 000 C Geometry of Object T 54750 55000 00000 gt 2 6 0000 20 0000 0 0000 saithe Ee 3 80000 20 0000 0 0000 El 4 BO 5 30 Coating Thin layer ends lt lt Bid Dimer uk thickne Imm _ End face inZ 3 0000 0 0000 000 0 1130 40 0000 Mesh Density Control Points z004 gt gt 200 1 035 s000 1200 7 035 2000 x yfmm densiy 1 0 30 f Gong 22070 tooo O Default View Asaocr 120p Ey A H 2 000 2 000 1 000 1 000 1 000 D bo m Fig 28 Location of density control points with indication of density scale 10 Click Generate Mesh the mesh will be automatically generated for all the materials in the combination Before mesh generation the connection or mounting of electrode to the machine has to be defined first as described in the Section 3 3 3 on machine settings The Mesh menu includes three items
7. a b Fig 11 Weldability lobe with varying weld current and force but constant weld time for spot welding of two 1 mm mild steel sheets 2011 SWANTEC Software and Engineering ApS www swantec com 29 SORPAS User Manual Version 10 6 Chapter 3 Using SORPAS In this chapter we will explain how to use SORPAS including e preparing input data e running simulations and optimizations e displaying and analyzing the results and e preparing and editing data in the databases The Input Wizard is a step by step procedure for preparing the input data which is described in Section 3 1 The data preparation for Weld Planning is explained in Section 3 2 More details for preparing and editing the input data are described in Section 3 3 The use and preparation of the Preferences are described in Section 3 4 The procedures for running simulations optimizations and Weld Planning are described in Section 3 5 The analysis and display of results are described in Section 3 6 The display of metallurgy results is described in Section 3 7 The display of results for residuals is described in Section 3 8 The databases are described in Section 3 9 and some other functions described in Section 3 10 3 1 Input Wizard The input data for simulations and optimizations of spot welding can be quickly and easily prepared with the Input Wizard in just 7 steps The input wizard can be activated for making new data file by clicking the menu item
8. ccc cccccscescecsssescssessssseuesssesessssasescssesesssescssssecssesecseesseseaseease 16 1 3 5 EQUCOPION ond TIMING c cece cece cece eee cece ee sese tesa su sesesecessesssuesecsesesecaeseesseecsssecseseeesseaeaees 16 CHAPTER 2 EXAMPLES vasssssssssssusnsssnsnsvesasssususnssssonsvainsncusesdsonsesdcnansnossbassosbasacesninenabasdensasosavssssadsnsivssasocarssscouse 17 ZSIS DA ss cces cscs E Ss cts E aaa canteen TAE eas Sanam arias 20 2 2 S 1l COATING DAT 29 32 ssistetescSiesds esos Se heeds he atc Mian Mecha hiens Sea OER 21 2 3 3 SHEETS DAT ceai eerie a eea ESE das asda Bld aaah Bai ara E EEGA 22 2 4 S1 S1_GAP FORCE DAT ccccccsceccscscssesesececsesseseseusssesessesessesesecsesssesessessssesesasaesesecsesseaesecsesaeaeeececseeaeaeees 23 2 5 S1 S1_GAP 2FORCE DAT cccccsceccscscssesesesecsessesesessusesessesessesecessessssesessessssesesassesesecsessesesecsesacaeeececsesaeeeees 24 2 6 DP TRIPWATERCOOL DAT s fscsciessceccdcccetssuns Sansezcesshuccelats cubsdetetoseuscs stlechesdancdses ibaik r ka si a is ibr ii ih iSS 25 2 7 CROSS WIRE DAT cceccsesscscsessesesccscssssesesessesesecsesssacsessesessesesecsessssesesaacsessesassesesecsesseaesecsesacseesaeaeeeeeeaes 26 2 8 S1 S1_GROWTH CURVE FIL WELD GROWTH CURVE cccccccssesesscscsssseseseesesssecscsesseececsessesesecsesecseeeeetseneees 27 2 9 S1 S1_LOBE TIME FIL WELDABILITY LOBE CURRENT TIME 0ccccscescsscsescseeseseceesesececsessesesecsesesseeececses
9. end face will x X x be added x z Z y r y y x x EO Os CR co Zz Y z T D D owa Zz B E M 39 g Angle to X axis 0 000 Cylinder S lt N lt N lt Tx Kh x x x x Define Circular End Face in Z Radius 1 000 R2 mm Any point on central axis 3 0 000 Y 11 550 mm Define Wedge End Face inZ Bottom Length Imm z able SORAS Cancel Fig 33 Data input window for defining the shape with end face in Z For modeling 3D geometries the shape of the selected object in the 3rd dimension can be defined with the bulk thickness in Z and the end face in Z as follows 1 Flat end face which is defined by a The bulk thickness in Z only 2 Ball end face which is defined by a The bulk thickness in Z equals O for standard ball or has a bulk thickness cylindrical piece combined with the ball end face b The radius of the ball c The coordinates of the central point of the ball 3 Cylinder end face which is defined by a The bulk thickness in Z equals O for standard cylinder or has a bulk block of the given thickness combined with the cylindrical end face b The radius of the cylinder c The coordinates of a point on the central axis of the cylinder d The angle of the central axis of the cylinder with respect to x axis 2011 SWANTEC Software and Engineering ApS www swantec com 51 SORPAS User Manual Version 10 6 4 Cone end face which is defined by a The bulk thickn
10. 0 500000E 01 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 1125E 04 0 0000E 0 0 550000E 01 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 1238E 04 0 0000E 0 0 600000E 01 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 1350E 04 0 0000E 0 _ 4 m Fig 60 Data sheet for simulation results of all process parameter curves 3 6 2 Nodal value curves Click on the menu item Nodal Temperature Curves a new window is displayed for specifying the nodal numbers to display nodal temperature curves see Fig 61 The nodal numbers can be obtained by displaying the mesh and then clicking twice on the menu item Mesh Nodal Number under the main menu item View or by displaying the Animation of Deformation and then clicking on the button Node If the check box Save nodal data in file is checked the nodal temperature data making the curves will be saved in a text file with a name consisting of the data file name attached with the nodal numbers and an extension name tem Press OK 2011 SWANTEC Software and Engineering ApS www swantec com 77 SORPAS User Manual Version 10 6 the temperature curves of the two nodal points through the whole welding process will be displayed as shown in Fig 62 p eae Making Nodal Temperature Curves xX Enter two node numbers for making nodal temperature curves Node 1 452 Node 2
11. it from the database 2 Material list e Duplicate button is to add a new material in the selected category with the same material data as the selected material e Add New button is to add a new material in the selected category with no material data listed e Remove button is to delete the selected material from the category and the database Three general operational buttons are located in the upper right corner of the material database editor e Save button is to save the material data into database e Cancel button is to close the editor of database without saving newly entered data e OK button is to close the editor and save the database Each material in the database is given a material ID which is used to identify the materials during simulations The material ID is universal and permanent This means that removing materials from the list will not affect the ID number of the other materials in the database The material ID is shown at the upper right corner of the window The number beside the material ID is the total number of materials in the database User added materials will start at ID number 1000 and then increase as they add more material data The Category List is a dropdown list of all the material categories in the database The Material List also a dropdown list is related to each category in the Category List Users may select any material to display the material data The name of the current category or material can b
12. settings are shown together with the results of simulation including a selected parameter curve and the final temperature distribution with weld nugget formation The maximum power requirement and total energy consumption of the welding process are also shown in the report which are useful for selection of welding equipment Examples of the report of simulation are shown in Fig 2 Fig 8 as described in Sections 2 1 2 7 3 6 7 Final Temperature Distribution and Weld Results 2011 SWANTEC Software and Engineering ApS www swantec com 82 SORPAS User Manual Version 10 6 The final temperature distribution with the weld nugget formation and weld strengths is shown as the final result of welding simulations The weld nugget diameter and height in each sheet are obtained and shown on the graph If splash occurred it is also shown with a graphical indication at the splash point Fig 66 shows an example of the final temperature distribution BB SORPAS s1 s1 dat o a File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help SORPAS R Version 10 1 E ise Editi so RO FS isss 2010 by SWANTEC Software and Engineering ApS All rights reserved Temperature C HE oe 1 560E 03 1 406E 03 1 252E 03 1 098E 03 9 440E 02 7 900E 02 6 360E 02 4 820E 02 3 280E 02 1 740E 02 Le Tm 2 000E 01 Proc time 300 000 ms Max T 2 496 4 T 25 1563 9 Nugge
13. system After knowing the basic procedures for making simulations it will be helpful to try a couple of simulations by just redoing the examples with the same conditions or with simple modifications remember first to duplicate the data file to a new file name with the Save As function before making modifications Opening single simulation examples The single simulation examples can be opened by clicking on the menu item File and then clicking Open Data File and then browse for the data file dat to be opened Opening batch simulation examples The batch simulation examples including the weld growth curve and the wedability lobes can be opened by clicking on the menu item File and then clicking Open Batch File and then browse for the batch file fil to be opened When a batch file is opened a series of the data files will be loaded while one data file is opened at a time whose name is shown at the top title bar 2011 SWANTEC Software and Engineering ApS www swantec com 18 SORPAS User Manual Version 10 6 Editing Data Files The detailed data of each data file can be seen and edited in the Input menu by clicking Edit Data File which include geometry materials machine and process parameters etc Viewing Simulation Results The results of simulation can be seen in the Results menu including the process parameter curves nodal value curves weld growth curves weldability lobes The final size of the we
14. the results are saved with an interval of every 10 steps for all welding stages or every 5 ms with the time step of 0 5 ms in the squeeze and every 2 ms with the time step of 0 2 ms in the weld time and every 10 ms with the time step of 1 0 ms in the hold time Include numerical models and define accuracy for convergence Depending on the interest of users or the nature of problems it is free to select which model s will be included in the simulation by simply clicking on the necessary model s Selection of thermal model will automatically include metallurgical model The example of spot welding includes all four models therefore all models have been selected Accuracy for convergence of the numerical procedures must be specified with respect to the electrical thermal and mechanical models Smaller value indicates higher accuracy of simulation but also increases the computation time since more calculations will be needed to achieve convergence A typical value is 10 Note Simulations are carried out with coupled interdisciplinary analysis including electrical thermal metallurgical and mechanical models The electrical model is for electric conduction and heat generation due to Joule heating The thermal model is for temperature development and heat transfer The metallurgical model integrated with the thermal model is for material properties and microstructures varying with temperature The mechanical model will calculate the deforma
15. will be displayed in the centre of the object instead of the object number The active object is highlighted in yellow color with red lines on the border in the graphics window The coordinates for the corner points shown in the list box at the right side can after selection be modified in the edit box at the left side The selected point is shown as a red dot in the graphics window The round corners or curved lines can be defined by giving the radius of the curve The curved line is always drawn from the current point the one with value of the radius to the next point connecting the two points A positive radius defines a convex round corner while a negative radius defines a concave round corer In order to avoid confusion in the orientation an exact half circle should be defined by two pieces of arcs by inserting a middle point Button gt gt is to insert point co ordinates below the selected point or otherwise to the end of the list lt lt is to remove the selected point and is to modify the selected point The contacting lines between objects should coincide or overlap each other precisely in order to ensure reasonable mesh generation and electric current conduction through the connection of objects The type of each object must be selected among Electrode Workpiece Coating solid materials or Interface artificial layer to represent the contact properties When Electrode Workpiece or Coating is select
16. 0 12 000 ize um C Ton F ANsheets Gap between sheets mm 0 00 Sheet No 1 Leb I Clamping in Y r Shest material Coating materia Category Steel alloys x Materiat AISI 1005 W Nr 1 0288 Hr x ELECTRODES Category Electrode materials Materiat ISO 5182 A22 Electrode C v ISO 5182 A2 2 Electrode C Electrode materials le Water cooling Water cooling Flow rate 4 000 Vin Flow rate 4 000 min Wate T 20000 c Water T 20000 Cc MACHINE Machine 002 AC Arbitrary rocker arm spot welding machine zi I Limitto Max Force of Machine Fmax 4 9 KN auauty Height 5000 Minimum weld nugget diameter 3500 Mm f innesi outer sheo Choose the weld curent at 35 of the splash expulsion imit User Prefered Parameters Elements 1000 _Mesh Start Ba Fig 19 The graphic user interface for preparing the Weld Task Description for Weld Planning 2011 SWANTEC Software and Engineering ApS www swantec com 37 SORPAS User Manual Version 10 6 It is also possible to set User Preferred Parameters with given values for weld force weld time or number of pulse see Fig 20 Setting a parameter at O will allow SORPAS to fully optimize that parameter In case of welding with multiple pulses it is possible to optimize selected number of pulses by giving the range of t
17. 0 000 ms Tmm Fig 72 Animation of deformation in the spot welding geometry When displaying animations of strain strain rate and stress options of the components will be asked among effective value component in X component in Y and component in XY see Fig 73 Fig 74 is an example of the distribution of the stress Component in Y vertical Select Component of Variable to Display C Effective value C Component in X Component in Y Component in XY shear Cancel Fig 73 Selection of component of variable to display 2011 SWANTEC Software and Engineering ApS www swantec com 87 SORPAS User Manual m FE SORPAS s1 s1 dat File Input Mesh Simulation BatchRun Optimization Weld Planning Results SORPAS R Version 10 1 Enterprise Edition so RO as C 1995 2010 by SWANTEC Software and Engineering ApS All ls Proc time 49 000 ms _ 7mm Max S 2 10 863 Min S 2 318 5 S 25 296 8 ISO 5182 A2 2Elec ASI 1005 W Nr 1 028 S 25 35 382 fale Version 10 6 Stress Y MPa 3 937E 01 9 662E 00 5 870E 01 1 077E 02 1 568E 02 2 058E 02 2 548E 02 3 039E 02 3 529E 02 4 019E 02 4 510E 02 Fig 74 Animation of normal pressure or vertical component of stress in Y 2011 SWANTEC Software and Engineering ApS www swantec com 88 SORPAS User Manual Version 10 6 3 7 Display Metallurgy Resul
18. 1 Enterprise Work DP TRIP_watercool dat Example 1 Computation time Number of Elements Materials Electrodes T 920 000 mm Type BO d2 8 d1 20 ISO 5821 2009 TRIP 700 H400T DP 600 SAE 32340 600D HC Design of Weld Combination d pi Machine 002 AC Arbitrary rocker arm spot welding machine Process Parameter Settings Current kA rms 8 5 kA 50Hz 40 0 1 600 Force kN L 120 L 0 800 L 0 400 0 000 Process time ms Pomar 26 8 KVA Etot 20715 Simulation Result Process Parameter Curve 5 916 5 324 4 733 aaa 2 549 Weld nugget size mm Simulation Result Temperature Distribution and Weld Nugget U M CC Molten 1 5006 03 Nugget Size at Interface A B D 5 916 mm 1 352 03 1 2046 03 1 056E 03 9 080 02 7 8008 02 6 1206 02 4 8406 02 3 1608 02 1 6808 02 2 000 01 Fig 7 The report of simulation generated by SORPAS for example s1 s 1_watercool the upper part is the welding conditions and the lower part is fhe main simulation results 2011 SWANTEC Software and Engineering ApS www swantec com 25 SORPAS User Manual 2 7 Cross Wire dat Version 10 6 The example Cross Wire is a simulation of the cross wire welding of steel wires with diameter of 2 mm One wire is perpendicular going in
19. 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved 5 229 J 4 706 Process Parameter Curves ma 4 183 7 i J Weld nugget size mm 3 660 a alj Scale la 3 137 7 2 614 7 2 091 J 1 569 Weld nugget size mm 1 046 0 523 J 0 000 T T T T T 1 0 0 60 0 120 0 180 0 240 0 300 0 Process time ms Fig 57 Process parameter curve showing the development of the weld nugget size as function of process time Fig 58 shows the control buttons lt and gt for searching through the process parameter curves or which can also be selected from the drop down list The scroll bar below the buttons is for locating the cursor and reading the values of the point on the displayed curve Fig 58 Control tool for parameter curves The button Seale is for changing the scale limits of the axis Fig 59 shows the dialog window for setting the scale limits of axis for displaying the parameter curves The same function can be used similarly for displaying all curves so long as the button Seale is activated 2011 SWANTEC Software and Engineering ApS www swantec com 76 SORPAS User Manual Version 10 6 Set Scale of Parameter Curve Vertical axis Lower scale limit Upper scale limit 0 000 5 229 Horizontal axis Lower scale limit Upper scale limit 0 000 300 000 Reset Cancel Fig 59 Setting scale limit
20. 461 Save nodal data in file Cancel Fig 61 Window for input nodal points to display nodal temperature curves r s n ZE SORPAS s1 s1 dat CIE File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help so BS SORPAS R Version 10 1 Enterprise Edition RO C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved 1971 0 J 1773 9 4 1576 8 7 1379 7 7 1182 6 i 985 5 J 788 4 g 591 3 7 394 2 i Nodal temperature C 197 1 7 0 0 T T T T l 0 0 60 0 120 0 180 0 240 0 300 0 Process time ms Fig 62 Nodal temperature curves Other nodal values can be displayed similarly except for that the nodal temperature and nodal current density will show as individual nodal value curves whereas the nodal voltage nodal resistance and nodal displacement will show the relative values between the two nodes the value of second nodal point shows at 0 An example of the nodal resistance curve is shown in Fig 63 2011 SWANTEC Software and Engineering ApS www swantec com 78 SORPAS User Manual Version 10 6 Similarly all nodal values used for making the curves can be saved in text files if the check box Save nodal data in file is checked when defining the nodal numbers see Fig 61 The file names will be made with the name of the data file attaching the nodal numbers with different extensi
21. 500 C has been recorded during the cooling process The peak temperature at the node shall have reached above 800 C and the actual temperature shall have cooled down below 500 C in order to get any value at the node Fig 78 is an example of the distribution of the cooling time from 800 C to 500 C ZE SORPAS DP TRIP_watercool dat o ea File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help S O RO 3 S SCZLFAS R Version 10 1 Enterprise Edition 7 C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved Cool time t8 5 s From 800 C to 500 C 0 291 0 262 0 233 0 204 0 175 0 146 0 116 0 087 0 058 0 029 le 7mm 0 000 Proc time 1 740 s Max t85 2 0 000 t85 0 291 t85 253 0 268 Min t65 2 0 000 t85 236 0 000 t85 253 0 000 ISO 5182 A2 2 Ele DP 60 23406 TRIP 700 H400T Fig 78 Distribution of cooling time from 800 C to 500 C 2011 SWANTEC Software and Engineering ApS www swantec com 92 SORPAS User Manual Version 10 6 3 7 4 Distribution of Volume Fraction of Austenization The austenization is calculated during the heating process according to the austenization temperatures namely the austenization start temperature Taci and full austenization temperature Tacs Fig 79 shows an example of the volume fraction of the austenization ZE soRPAS DP TRIP_watercool dat k
22. 672 1 Tp 236 2300 3 Tp 253 22946 Min Tp 2 35 532 Tp 236 108 9 Tp 253 94 216 ISO 5182 A2 2Elec DP 600 SAE 32340 6 TRIP 700 H400T Fig 76 Distribution of peak temperature 2011 SWANTEC Software and Engineering ApS www swantec com 90 SORPAS User Manual Version 10 6 3 7 2 Distribution of Cooling Rate at 700 C The cooling rate at 700 C has been recorded during the cooling process It is obvious that the peak temperature at the node shall have reached above 700 C and the actual temperature shall have cooled down below 700 C in order to get any value at the node Fig 77 is an example of the distribution of the cooling rate at 700 C ZE SORPAS DP TRIP_watercool dat 2o ka File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help SORPAS R Ve 10 1 Ente Editi so RO as C 1995 2010 i fatale eebe ee ApS All rights reserved Cool rate log Cr7 700c 7 128 6 415 5 703 4 990 al _ 3 564 2 851 2 138 1 426 0 713 0 000 Proc time 1 740 s Max Cr7 2 0 000 Cr7 ahd 7 109 Cr7 253 7 068 Min Cr7 2 0 000 cr7 0 000 Cr7 ER 0 000 SO 182 A2 2 lec DP 600 3406 R 2007 Fig 77 Distribution of A rate at 700 C 2011 SWANTEC Software and Engineering ApS www swantec com Sols SORPAS User Manual Version 10 6 3 7 3 Distribution of Cooling Time from 800 C to 500 C The cooling time from 800 C to
23. Cancel Fig 38 Window for multiple welds options Fig 39 shows an example of the simulation result for the temperature development at the electrode tip with multiple welds BE SORPAS m2 dat File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help SORD SS Cisse colo by SWANTEC Software and Engineering ApS Al rights reserved 532 822 7 F f f 479 540 J 426 258 4 372 975 i J 319 693 7 266 411 213 129 159 847 7 Nodal temperature C 106 564 53 282 0 000 T T T T 0 0 880 0 1760 0 2640 0 3520 0 Process time ms Fig 39 Temperature development at the electrode tip with multiple welds 2011 SWANTEC Software and Engineering ApS www swantec com 61 SORPAS User Manual Version 10 6 3 3 6 Define optimization procedures In order to further increase the efficiency of simulations several automated procedures have been implemented in SORPAS including generation of the weld growth curve weldability lobes and verification of the contact resistance factor After setting up the parameters as described below the optimization procedures can be started as described in Section 3 5 3 Automated procedures for optimization of weld current As shown in Fig 36 clicking on Optimization of weld current will activate the window for specifying the automated procedures fo
24. File Fig 51 Menu items of Optimization with active item for weldability lobe After the optimizations are finished the results can be viewed by Open Batch File under main menu File and then select the batch file with the same name as the initial data file which was used to start the optimization procedure When the procedure for verification of contact resistance is selected and defined as described in Section 3 3 6 the menu item Verification of contact resistance is 2011 SWANTEC Software and Engineering ApS www swantec com 71 gt SORPAS User Manual Version 10 6 activated as shown in Fig 52 Clicking on it the automated procedure for verification of the contact resistance factor will start and the data file will be modified iteratively When the simulated weld nugget size reaching the given tested weld nugget size the simulation will be finished and new values of the contact resistance multiplier will be obtained as read in Fig 21 with the data file editor Optimization of Weld Current Generation of Weld Growth Curve Generation of Weldability Lobe Verification of Contact Resistance Continue from Current Data File Continue from Latest Simulated Data File Fig 52 Menu items of Optimization with active item for verification of contact resistance Continue from Current Data File is to continue the optimization procedure from the currently opened data file If the optimization procedure was st
25. Interface H smaller Modify splash limit 0 H el Workpiece Material Category Steel alloys id Material AISI 1005 w Nr 1 0288 Hr C0 06 Mn0 35 sd Coating Material Category Surface coatings Lols Material Zine Galvanize Electrode Material Category Electrode materials Material ISO 5182 A2 2 Electrode CuCrZr Ll Electrode Form Type BO d2 6 di 16 1S0 5821 2009 l4 Welding Machine I Limit Parameters to Machine Capabilities Machine 002 AC Arbitrary rocker arm spot welding machine Process Parameter Settings Force kN C pounds Time Milliseconds Cycles Squeeze time Weld time Hold time Off time Idle time 2000 fio 000 fs ooo fo ooo fo o00 cycle Frequency 50 000 H2 C By volage By curent By power Simulation Control Time step 0 500 fo 200 1 000 1 000 fio oo0 ms Save data per 10 5 10 10 10 steps Elastic Loading Thermal Stresses Unloading Residuals Fig 44 Preferences 2011 SWANTEC Software and Engineering ApS www swantec com 66 SORPAS User Manual Version 10 6 3 5 Running Simulations Before starting the simulation the finite element meshes must be properly generated A correctly generated mesh is shown in Fig 45 There must be red boundary lines in connection to the tools in order to ensure the weld current and force correctly applied to the electrodes and light blue
26. Strain rate distribution Stress distribution All animations of the parameter distributions are controlled with the control tool as shown in Fig 67 An example of the animation of temperature distribution example s1 s1 dat is shown in Fig 68 The welding time and the maximum values of the parameters in each material are displayed at the bottom of the window Animation Control Isotherm Nugget Mesh Scale Image Zoom i Fig 67 Control tool for animated display of parameter distributions Goto k lt Ik gt gt Il 2011 SWANTEC Software and Engineering ApS www swantec com 84 SORPAS User Manual E sORPAS s1 s1 dat File Input Mesh Simulation BatchRun Optimization Weld Planning Results S O RO 3 S SC2FAS R Version 10 1 Enterprise Edition T C 1995 2010 by SWANTEC Software and Engineering ApS All Le Proc time 146 000 ms Nugget min 4 845 Nugget max 4 845 Timm Max T 2 684 3 T 25 Melt T 2 1070 0 25 ISO 5182 A2 2Elec AS 1 028 Version 10 6 Animation Control Isotherm Scale Image Zoom OK k lt gt l f f1 Goto gt gt 1 Nugget Mesh Ik Temperature C HE oten 1 560E 03 1 406E 03 1 252E 03 1 098E 03 9 440E 02 7 900E 02 6 360E 02 4 820E 02 3 280E 02 1 740E 02 2 000E 01 Fig 68 A In Fig 67 button Isotherm is for options nimation of temperature distributio
27. Task 490016 100317 152829 Weld Planning Report Filename C SORPAS 10 1 Enterprise Work s1 s1 dat Problem ID Spot welding Computation time 0 03 52 Note steel 1 mm steel 1 mm Number of Elements 956 Materials Design of Weld Combination Optimization Result WSS Optimal Weld Schedule Specifications Electrodes 2 240 7 16 000mm Type BO d2 6 d1 16 i 2016 ISO 5182 A2 2 Elect 1 792 G 816 000mm p F 1 568 q F 1 348 Fo 1 120 P o 896 Workpieces 5 1 000mm AISI 100S W Nr 1 0288 Force kN 0 672 AISI 100S W Nr 1 0288 0 448 Machine 002 AC Arbitrary rocker arm spot welding macht max 9 0 KA P max 28 0 KVA F max 4 9 KN Current kA 0 224 gt 0 000 Toms 8 3 kA 50Hz Process time ms Optimization Result Welding Process Window and Optimal Param Optimization Result Weld Qaulity Result at Optimal Parameters 7 000 ee Nugget Size at Interface Current 8 27 kA a voten 6 300 KN 1 560E 03 Aa B D 5 229 mm orce 2 24 5 600 Weld Time 8 cycles 1 406E 03 4 300 Hold Time 5 cycles 1 252E 03 pepe 41 0956403 9 440E 02 3 500 7 900E 02 2 800 6 360E 02 2 100 4 820E 02 1 400 3 280E 02 0 700 4 1 740E 02 ooo 2 000E 01 22 44 Weld current KA Weld Nugget Size mr Fig 65 Weld Planning Report 3 6 6 Report of simulation In the Report of Simulation the initial conditions and the weld process parameter
28. applications seven examples for single simulation one example for weld growth curve and two examples for weldability lobes are included in the software package The descriptions and purposes of the examples are presented in Table 1 Table 1 The examples and their purposes Filename How to open Description Purposes of the example s1 s1 dat File gt Open Data File Spot welding of two 1 mm mild steel sheets To show the basic procedures for data preparation and results of simulation 1 s1_Coating dat File gt Open Data File Spot welding of two 1 mm mild steel sheets with galvanized coating To show how to simulate spot welding of materials with coating 3 sheets dat File gt Open Data File Spot welding of 3 sheets with 0 8 mm low carbon steel 1 5 mm HSLA and 1 5 mm DP600 To show how fo simulate spot welding of 3 sheets with dissimilar metals and different thickness and the difficulty of welding the thin low carbon steel s1 s1_Gap 1force dat File gt Open Data File Spot welding of two 1 mm mild steel sheets with a gap between the sheets before welding Only upper electrode is moving by force To show how to simulate spot welding with gap between the sheets before welding s1 s1_Gap 2force dat File gt Open Data File Spot welding of two 1 mm mild steel sheets with a gap between the sheets before welding Both electrodes are moving
29. clockwise or the tools were un defined Proposed way to solve the problem Check the co ordinates of the tool and correct the errors ERR1005 The given radius does not fit This error occurs usually due to incorrect definition of the radius at a round corner Proposed way fo solve the problem Check the co ordinates and radius at the round corners and correct the errors ERR1101 Solution failed due to null resistivity data This error occurs when at least one of the materials had zero resistivity Proposed way fo solve the problem Check the entire list of resistivity data for every material and remove the zero values ERR1102 Solution failed due to null thermal conductivity data This error occurs when at least one of the materials had zero thermal conductivity Proposed way to solve the problem Check the entire list of thermal conductivity data for every material and remove the zero values ERR1103 Solution failed due to null heat capacity data This error occurs when at least one of the materials had zero heat capacity Proposed way fo solve the problem Check the entire list of heat capacity data for every material and remove the zero values ERR1104 Solution failed due to null density data This error occurs when at least one of the materials had zero density 2011 SWANTEC Software and Engineering ApS www swantec com 112 SORPAS User Manual Version 10 6 Proposed way to so
30. electrode force The total number of tools may be up to 10 but minimum 2 for application of the force and the electric current The scroll bar is used to search the tools Note Tool No 1 is always assumed to be the tool to conduct current from machine to electrode Tool No 2 is always assumed to be the opposing tool to complete the electric circuit More tools can be added for mechanical support but any tool from no 3 will not work with electrical system Click the Insert button to open the Inserting window see Fig 35 A new tool can be inserted as a Duplicate the Current Object highlighted in yellow color as a Rectangle defined by a width and a height or as a New to be defined by user After choosing the shape of the tool the Position to insert must be selected The tool can be inserted On Top or Under Bottom of the existing geometries or it can be located At Position defined by x and y in mm Tool 1 and Tool 2 in the spot welding example are inserted as Rectangle respectively on top and under bottom of the existing electrodes 2011 SWANTEC Software and Engineering ApS www swantec com 54 SORPAS User Manual Version 10 6 Inserting Select Object to Insert Duplicate the Current Object C Sheet Rectangle Ww H tone C wh Sf Him C Plate 1 0 mm zH c Type AO di 13 P1 30 150 zH C New From Text File List of xy Select Position to Insert OnTop Under Bottom C At Posit
31. graphics 3 3 2 Define 3D geometries with the Block Model Many of 3 dimensional geometries with mixed cylindrical or sohere shapes and cubic blocks can be modeled by the 2 5D treatment developed in SORPAS 2011 SWANTEC Software and Engineering ApS www swantec com 49 SORPAS User Manual Version 10 6 To define 3D geometries the Block Model has to be used The geometries of the objects are first defined on the x y plane as displayed on the screen The thickness of the object in Z the 34 dimension can be given individually for each object in the edit box Bulk thickness in Z The end face of the selected object in the 3rd dimension can be defined by the function End face in Z Fig 32 shows the geometry of the included example of Cross Wire dat where the object no 3 is defined as a cylinder in Z Fig 33 shows the required variables for defining the different types of end faces in Z f E iil FE SORPAS Cross Wire dat Clea File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help SORPAS R Version 10 1 Enterprise Edition Reset Zoom Image SaveAs Save Undo canca ok SO RO 3 S Cisse 2010 by SWANTEC Software and Engineering ApS All rights reserved Problem ID name Cross Wire Note DC d Geometry and Materials Machine Settings Simulation Control Type of Geometric Model Type of Symmetry Line y
32. gt x lt lt kN C pounds lt S soon L 180 amp Electrical Control C Byvoltage B tC B E Ss 2 y voltage By current By power E ame PRF thoga Puses H nofi Frequency 50 000 Hz 5 s799 L oso L O ses 9 600 Up slope Weld Down slope Cool ane L 0 300 Profile 0 000 10000 H 0o00 cycle lt 50 gt 0 000 RMS 8 000 H kA Cond Angle 80 0 Process time ms 3 Fig 34 Input window for machine settings Define the welding process time in five stages Squeeze time Weld time Hold time Off time and Idle time Similar to programming a welding machine the squeeze time the weld time the hold time and the off time can be specified The welding process time can be specified either by milliseconds or by the number of cycles The squeeze time should be set longer than the time needed to build up the electrode force to allow the weld force and deformation of materials to stabilize It should be mentioned here that the actual squeeze time in the real welding process is a parameter depending on individual welding machines In many cases the necessary squeeze time of a specific welding machine at a specific welding force can be found by simple loading test This squeeze time should be used in the actual welding process In the numerical simulation the building up of electrode force can be much faster than in the actual welding process In order to s
33. hold time according to the user defined Weld Task Description WTD with information of the sheets electrodes type of weld machine and the desired weld quality see Fig 19 A Weld Task Number is assigned or manually defined by the user for identification of the weld task The procedures for defining the sheets and selecting electrodes and welding machine are similar to the Input Wizard as described in Section 3 1 for steps 3 5 When the check box Limit to Max Force of Machine is checked the maximum force capable to be delivered by the welding machine given in the Machine Database will be used as the limit of the weld force during the optimizations The optimal welding parameters together with the welding process window will be predicted by SORPAS The optimal weld current is then chosen at a preferred percentage to the splash expulsion limit soecified by the user BB SORPAS st si dat fe ea ls File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help SORPAS R Version 10 6 Enterprise Edicion WID Weld Task Desciption Saves Save Cancel ok gt O RO 3 S jiss 2011 by SWANTEC Software and Engineering ApS All rights reserved Weld task name 1 Note steel mm steel mm SHEETS Number of sheets to be welded 2 Dimension and material of each shest Thickness mm Thickness per side um Width mm 4 Sheet 1 000 Coating 0
34. lines along the free boundaries ZE sORPAS s1 s1_watercool dat o a File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help S O RO 3 S SORAS R Version 10 1 Enterprise Edition 7 C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved Le oe Tha Elements 961 Nodes 1099 Fig 45 Correctly generated mesh 3 5 1 Run process simulation for single weld or multiple welds After all the necessary data are prepared and mesh generated correctly the process simulation for single weld and multiple welds can be started by clicking the menu item Simulation in Fig 1 then selecting New Simulation as shown in Fig 46 New simulation is to start simulation with the currently opened data file from the initial state of the welding process time 0 Continue is to continue an interrupted simulation from where it was stopped 2011 SWANTEC Software and Engineering ApS www swantec com 67 SORPAS User Manual Version 10 6 New Simulation Continue Continue in Off time to Complete Phase Transformations Continue from Other Data File Online Simulation Mode Fig 46 Menu items of Simulation The grayed functions are not yet implemented in the current version Continue from Other Data File is to continue from another data file with finished simulation whereas the new simulation will first copy results from the other sim
35. the animation step by step Button gt is to play the animation automatically Button gt is to forward the animation step by step or stop the automatic play Button and are to control the soeed of animation with 1 for normal speed or 2 5 10 20 and 50 times of the normal speed and also 1 2 and 3 for slower animation Button Go to is to go to a specified welding time Button gt gt is to fast forward to the end Button OK is to close the animation The animation of deformation is managed by the control tool shown in Fig 71 that is similar to the control tool for animation of parameter distributions shown in Fig 67 But there are two special buttons for checking the co ordinates of nodal points Button Node is to display the nodal numbers and Coord for displaying the co ordinates of two nodal points An example of the animation of deformation is shown in Fig 72 Animation Control Coord Mesh Node Image Zoom F Goto k lt Ik gt rl fi Fig 71 Control tool for animated display of deformation 2011 SWANTEC Software and Engineering ApS www swantec com 86 SORPAS User Manual Version 10 6 ZE sorpas s1 s1 dat Animation Control fo amp e File Input Mesh Simulation BatchRun Optimization Weld Planning Results Coord Nugget Mesh Node Image Zoom OK k lt Ik gt al f f1 Goto gt gt 1 Proc time
36. 000 A kia MPa Thermal Expansion Coefficient padrao j200 R gt ee ne Ultimate Tensile Strength 320 MPa T CC TEC 10 6 C Elk 300 000 13 500 X s Young s Modulus of Elasticity Elongation at Break 45 2 Bae 2000 200 000 Strain Hardening Exponent nj 0 000 TCC E GPa GPa kN mn wee lt lt Poisson s Ratio R gt 25 000 0 300 Weld Strength Factors T C PR IET ES Cross Tension Strength factor 1 000 Flow Stress Curve A p Ss 20 000 358 000 0000 0120 0 020 Tensile Shear Strength factor 1 000 z A 100 000 401 000 0 000 0130 0 030 TCC C MPa Banm FS Ce B n m _ _ lt lt 200 000 412000 0 000 0140 0 050 X Peel Strength factor 1 000 File Name Material dbs Category Pure Metals z Material Cu Copper si Load Selected Category Load Selected Material Fig 87 Loading materials data from other material database file Other functions for editing the category and the material data are described below 1 Category list e Duplicate button is to add a new category at the end of the category list including the same material list as in the selected category 2011 SWANTEC Software and Engineering ApS www swantec com 99 SORPAS User Manual Version 10 6 e Add New button is to add a new category at the end of the category list with no material listed e Remove button is to delete the selected category including all materials in
37. 1 2526 03 1 098 03 9 4406 02 7 900E 02 6 360 02 4 8206 02 3 280 02 1 7408 02 2 000 01 Simulation Result Temperature Distribution and Weld Nugget Nugget Size at Interface A B D 5318 mm Fig 6 The report of simulation generated by SORPAS for example sl s1_Gap 2force the upper part is the welding conditions and the lower part is fhe main simulation results 2011 SWANTEC Software and Engineering ApS www swantec com 24 SORPAS User Manual 2 6 DP TRIP_watercool dat Version 10 6 The example DP TRIP_watercool describes a spot welding of 1 2 mm TRIP700 steel to a 1 5 mm DP600 steel with water cooling in electrodes The cooling process is fully completed therefore all metallurgical and residual results can be shown with this example The electrode is type B with conical tip face of diameter of 8 mm The process parameters used for the simulation are shown in Table 7 and the report of simulation generated by SORPAS is shown in Fig 7 Table 7 Weld parameters for example s1 s1_watercool Filename Squeeze Weld Hold Off Current Current Force time time time time RMS type ms ms ms ms kA kN DP TRIP_ 40 200 1000 500 8 5 AC 40 watercool dat ee ee a BSS ee re rasan Simulated with SORPAS R Version 10 1 Report of Simulation Simulation finished 20 04 2010 13 38 39 Filename Problem ID Note C SORPAS 10
38. 1 2526 03 1 0986 03 9 4406 02 7 9008 02 8 3806 02 4 9206 02 3 2806 02 1 7408 02 2 0006 01 Fig 8 The report of simulation generated by SORPAS for example Cross Wire the upper part is the welding conditions and the lower part is the main simulation results 2011 SWANTEC Software and Engineering ApS www swantec com 26 SORPAS User Manual Version 10 6 2 8 s1 s1_growth curve fil weld growth curve The weld growth curve can be simulated with a series of data files automatically created with increasing weld currents from a lower limit 2 kA to a higher limit 15 kA with an increment 1 kA The series of data files are automatically generated in a sub folder and included in the batch file s1 s1_growth curve fil It can be opened by Open Batch File After opening this batch file the simulated weld growth curve is displayed as shown in Fig 9 Fig 9a is the weld growth curve with weld nugget diameters Fig 9b is the weld growth curve with weld Cross Tension Strengths The red points indicate splashes expulsions at the interfaces between the sheets or over sized weld nuggets the purple points indicate electrode melting simulation can be set to automatically stop when the electrode melts which will result in slightly smaller nugget due to unfinished simulation The black points with open markers indicate no weld and that with solid markers indicate undersized welds The green point
39. 11 SWANTEC Software and Engineering ApS www swantec com 98 SORPAS User Manual Version 10 6 Material Database sd Material from Database F save Cancel ox Remo Add New Duplicate Remove dd Ne Duplicate Category Steel alloys v Material AISI 1008AW Nr 1 0338 Hr CO 10 Mn0 40 Material ID 3 Total in Database 25 Name Steel alloys Name AISI 1008 W Nr 1 0338 Hr CO 10 Mn0 40 SORPAS Classification Code 01 00 02 00 oo ooo HAZ T 700 000 C Solidus 1560 000 C Liquidus 1560 000 C Latent Heat of Fusion 277 000 kJ kg Metallurgical Data for Steels r Thermal Conductivity Cabon Equivalent Inina quivalent CE 0 104 T CL TC W mK lt lt 200 000 53 300 A Austenization Temperatures H Heat Capacity Act 718 000 Ac3 833 000 C Ls 20 000 481 000 a T CLHC U koK Tal 150 000 519 000 Martensite formation Temperatures d g JE pst 200 000 536 000 z HS Mass Density M start 484 000 M finish 284 000 C gt 20 000 7871 000 Critical Cooling Rates for Martensite TCC MD kg n Ed Full 5400 000 Start 3744 000 C s Resistivity Reading from CCT diagram gt 20 000 0 142 a TCCIA fu Ohmm lt 1000 a Hv f127 000 949 000 CE 21 000 log tr7 f Surface Contaminants Resistivity 2 LEA m gt gt a om an ooo Mechanical Properties at Room Temperature TCC Re p Ohm l 150 000 12
40. 2 5 235E 02 4 820E 02 4 406E 02 3 991E 02 3 577E 02 3 163E 02 2 748E 02 2 334E 02 1 919E 02 Le Proc time 1 740s Max T 2 236 3 T 236 5649 T 253 539 5 Melt T 2 5 T 236 280 o T 253 194 9 ISO 182 A2 2Elec DP 600 SAE 323406 TRIP 700 H400T 7 1 505E 02 7mm Fig 83 Distribution of Padua stresses in radial direction 3 8 2 Distribution of Cracking Risks Fig 84 shows an example of the distribution of the cracking risk The cracking risks have been estimated with the residual stresses the hardness and the critical cracking strain of the materials 2011 SWANTEC Software and Engineering ApS www swantec com 96 SORPAS User Manual Version 10 6 ZE SORPAS DP TRIP_watercool dat File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help 2 ea S O RO 3 S S2RPAS R Version 10 1 Enterprise Edition z C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved bo a Tmm Proc time 1 740 s T 236 0 099 T 253 T 236 0 026 T 253 DP 600 SAE J 6 TRIP 70 4 Cracking risk factor 0 099 0 089 0 080 0 071 0 061 0 052 0 042 0 033 0 024 0 014 0 005 Fig 84 Distribution of cracking risk factor 2011 SWANTEC Software and Engineering ApS www swantec com 97 SORPAS User Manual Version 10 6 3 9 D
41. 20 000mm Type Bi so 51 1 020 000mm Tyr ps um Zin 1500mm DP 600 7 0um Zinc G SAE 32340 340X E 32340 600D HC Machine 002 AC Arbitrary rocker arm spot welding machine Current kA rms 10 9 kA 50Hz Process time ms 940 0 EY 1712 L 1 284 L osse L 0 428 lt P 0 000 Pomar 37 2 KVA Et 7099 70 Force kN Simulation Result Process Parameter Curve 6 195 5 575 4 986 4 338 3717 3 087 2478 1 858 1 239 Weld nugget size mm 0819 0 000 Simulation Result Temperature Distribution and Weld Nugget Nugget Size A BC D 6195 mm ABC D 7 827 mm 3 2806 02 1 7408 02 2 000 01 Fig 4 The report of simulation generated by SORPAS for example 3 sheets the upper part is the welding conditions and the lower part is the main simulation results 2011 SWANTEC Software and Engineering ApS www swantec com 22 SORPAS User Manual 2 4 s1 s1_Gap 1force dat Version 10 6 The example s1 s1_Gap 1lforce is to illustrate how spot welding with a gap of 0 2 mm between the sheets before welding can be simulated The electrode is type B with conical shape and a tip face diameter of 6 mm In this example only the upper electrode is moving with controlled force The process parameters used for the simulation are shown in Table 5 and the report of simulation generat
42. 30 0 0000 co ssw oo seori MoveP 1o00 ooo 30 000 2500 0 104 0 000 SJ 6500 243 0 000 6 500 18 000 0 000 5000 18 000 0 000 4575 9 500 0 000 Bi Formula for Circular Tip Face Cut Tip face curvature R Tip face radius r Tip face cut height h 0 000 h R sqt P so RO BS SORPAS R Version 10 1 Enterprise Edition C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved 6 5000 2 4130 O Fig 88 Editor for electrode database The elevated height of the corner of the dome shaped electrode tip face can be calculated with a formula derived according to the geometric relations h R WVR r where R is the radius of the tip face curvature big circle r is the tip face radius and h is the tip face height as illustrated in Fig 88 Giving the values of R andr the value of h will be automatically calculated as shown in Fig 89 Fig 89 Illustration of the dimensions at electrode tip face h 2011 SWANTEC Software and Engineering ApS www swantec com 104 SORPAS User Manual Version 10 6 3 9 3 Workpiece database A great number of different workpiece designs are often used in resistance welding for example plates in soot welding and plates with embossed projection in projection welding implying that many workpiece designs can be used again and again in many different simulations A workpiece database with pre defined workpieces is therefore included in the
43. 4 SORPAS User Manual Version 10 6 Before You Start System Requirements SORPAS is professional welding software for simulation and optimization of resistance welding processes directly for industrial applications The following system specifications are recommended Operating system Windows XP Vista Windows 7 Processor 2 0 GHz or higher RAM 1 GB or higher Hard disk free space 10 GB or higher Graphic mode resolution 1024x768 or higher It is always beneficial to use the fastest computer available For an efficient computation speed especially for optimization procedures the processor speed shall be preferably faster than 2 5 GHz Installation of SORPAS Depending on the method of delivery the procedure for installation is as follows Delivery by CD Insert the CD of SORPAS into the CD drive of the licensed computer The installation program will start automatically In case the installation procedure is not started automatically click the Start menu of Windows and click Run then type the following and click OK D Install if the CD drive is other than D type the correct letter instead Follow the instructions to go through the installation procedures Delivery by Web downloading All licensed users have obtained a special link to their user account at the website of SWANTEC on which the user information and links to downloading are stated 2011 SWANTEC Software and Eng
44. 95 2010 by SWANTEC Software and Engineering ApS All rights reserved Simulated with SORPAS R Version 10 1 Simulation finished Report of Simulation 01 03 2010 12 00 00 Filename C SORPAS 10 1 Demo Workis1 s1 dat Problem ID Example 1 Note Computation time Number of Elements Materials Electrodes T 016 000mm Typ nse 1 016 000mm Tyr nse Worl Design of Weld Combination ISO 5821 2009 cu ISO 5821 2009 cu AISI 1005 W Nr 1 0288 Hr AISI 1005 W Nr 1 0288 Hr Machine 002 AC Arbitrary rocker arm spot welding machine Process Parameter Settings 11 814 2 260 5 907 2 953 Current kA 2 280 11 814 I_ems 8 3 kA 50Hz Process time ms Force KN Simulation Result Process Parameter Curve Simulation Result Temperature Distribution and Weld Nugget Fig 2 The report of simulation generated by SORPAS for example sl s1 The upper part is the welding conditions and the lower part is the main simulation results 2011 SWANTEC Software and Engineering ApS www swantec com 20 SORPAS User Manual 2 2 s1 s1_Coating dat Version 10 6 The example s1 sl1_Coating is to show how surface coating can be introduced and simulated The electrode geometry and the sheets are the same as in example s1 s1 The process parameters used for the simulation are shown in Table 3 and
45. AS User Manual 3 10 2 Help lt Clear Screen Save Image As Zoom Mesh Nodal Number Isotherm Line Fill in Nugget Outline Show Weld Nugget Sizes Show Splash Set Scale Show Full in Symmetry Hide Electrodes Hide Workpieces Fig 92 Menu items of View Version 10 6 The Help menu in Fig 1 includes two items as shown in Fig 93 The Valid Period is to check how many days the program will be functioning The About SORPAS is the information about the program and the authorized user and the product ID number 2011 SWANTEC Software and Engineering ApS www swantec com Valid Period About SORPAS Fig 93 Menu items of Help 110 SORPAS User Manual Version 10 6 Chapter 4 Error Messages 4 1 Errors related to data files ERROOO1 Invalid version of the data file This error occurs when an invalid version ID number in the data file is found not belonging to any of the released versions This may only occur when the data file was modified manually or generated with a newer version Proposed way to solve the problem Send the data file to the developers for checking and correcting the errors ERROOO2 Invalid data encountered The data file was damaged This error occurs when a wrong type of data found in the data file usually due to manual modification of the data file Proposed way to solve the problem Send the data file to the developers for checking and co
46. Batch File After opening this batch file the weldability lobe is displayed first with weld nugget diameters see Fig 10a The red color points indicate oversized weld nugget or splashes at interfaces between sheets The orange color indicates a profound likely hood of splash occurring The purple color points indicate electrode melting The gray color points with open markers indicate no weld and solid markers indicate undersized welds The green points indicate welds with a weld nugget in between the maximum and minimum weld nugget diameters as seen in Fig 10a The weldability lobe can also be shown with Cross Tension Strength Shear Strength and Peel Strength see Fig 11b where the open markers indicate Interface Failure and solid markers indicate Plug Failure More details on how to prepare data for making the weldability lobes are described in Section 3 3 6 a b a oo a p o M o o o unu n n mn n n a b Fig 10 Weldability lobe with varying weld current and time but constant weld force for spot welding of two 1 mm mild steel sheets 2011 SWANTEC Software and Engineering ApS www swantec com 28 SORPAS User Manual Version 10 6 2 10 s1 s1_lobe force fil weldability lobe current force The weldability lobe can be simulated with a series of data files automatically created with two varying process parameters in this case the weld current and the weld time It is organized by increasing weld force from a lowe
47. CD is shown at the beginning of the machine name more details are described in Section 3 9 4 It is possible to limit the process parameters to the machine capabilities by checking the check box Limit to Machine The frequency e g 50 Hz or 60 Hz for the weld current is defined in the Preferences more details are described in Section 3 4 It is possible to define multiple pulses with individual RMS value of current for each pulse Up slope and down slope can be defined for each pulse It is also possible to define a stepped current if the cooling between the pulses is set as 0 EE SORPAS 1 1 dat ajte jfa File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help sorpa S SORPAS R Version 10 1 Enterprise Edition C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved Electrical Process Parameters Milliseconds Cycles Machine 002 AC Arbitrary rocker arm spot welding machine X I Limitto Machine Imax 9 0 kA F max 4 9 kN Electrical Control C Byvoltage Bycurent C By power Pulses 1 H Noli afe Frequency 50 000 H2 Up slope Weld Down slope Cool Profile 0 000 foo foo eycle RMS 8 000 ka Cond Angle 80 0 sorgas Cancel Save lt Back Next gt Current kA Force kN Process time ms Fig 16 The Input Wi
48. E is the strain rate m is the strain rate exponent The parameters for the flow stress are input at each temperature with the four constants C B n and m see Fig 86 For every material a SORPAS Classification Code has been introduced with 6 numbers to define the following Category Class Grade Heat treatment Surface condition Batch number A new section has been added in the material database for the metallurgy data which is associated with every material They are needed for simulation of the metallurgical results such as distribution of harness and microstructures The Mechanical Properties at Room Temperature are data useful for verifying the flow stress curves at room temperature but not directly used in simulations However the Elongation at Break is used when calculating the Cracking Risks The Weld Strength Factors are used for correcting the predicted weld strengths when the user has made verifications with real weld tests and found the correlation factors between the simulated and tested weld strengths respectively 3 9 2 Electrode database 2011 SWANTEC Software and Engineering ApS www swantec com 101 SORPAS User Manual Version 10 6 Spot welding are characterized by a great number of standardized electrodes which are recommended for specific workpieces and weld situations but also in projection welding many electrode design can be used for different weld situations These electro
49. File and then clicking New Input Wizard or for editing existing data file by clicking Input and then clicking Edit Input Wizard Step 1 Define the file name and Problem ID Each case of simulation and optimization shall have a unique file name for the data files to store all input data and to save simulation results The Problem ID Name and the Note can be defined to identify the case see Fig 12 2011 SWANTEC Software and Engineering ApS www swantec com 30 SORPAS User Manual Version 10 6 SORPAS R New Input Wizard Step 1 Ee The new data file to be created is CASORPAS 10 1 Enterprise Work s1 s1 dat Problem ID name Spot Welding Note steel 1mm steel 1mm SOR9 S Coca _Net gt Fig 12 The Input Wizard step 1 to define the data file name the problem ID name and note Step 2 Select welding process The data input and preparation procedures in the Input Wizard are mainly designed for spot welding The Go to gt gt Welding Planning button will directly get to the window for defining Weld Task Description WTD for planning optimal welding parameters more details in Section 3 2 If projection welding or other resistance welding processes are to be simulated the Edit Data File window will be used which is more flexible with more detailed data for preparing complex problems please refer to Section 3 3 for further details ie i SORPA
50. Generate Mesh is to generate mesh automatically according to the input geometry data and mesh density control View Mesh is to display the existing mesh data Fig 29 shows the spot welding geometry with generated mesh Advanced is a function for refining a specific object with user defined number of elements see Fig 30 This function is only necessary when a local area or small part needs more elements for example in some micro welding applications 2011 SWANTEC Software and Engineering ApS www swantec com 47 SORPAS User Manual Version 10 6 E sorPAS s1 st dat CIE File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help so I S SORPAS R Version 10 1 Enterprise Edition RO C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved Reset Zoom Image SaveAs Save Undo Cancel Problem ID name Example 1 Note Geometry and Materials Machine Settings Simulation Control 7 Type of Geometric Model Type of Symmetry Line Axisymmetric model Vertical symmetry line x 0 a Block model Model 1 of mi symmetric division s z Elements 1000 Advanced Delete Inset Size Move Mee objeti gt Definition of the Current Object Electrode Work piece C Coating C Interface Category Electrade materials 2 Cee Material IS0 5182 A2 2 Electrode CuCizr E 4 ID 2 Init
51. PAS Simulation with SORPAS is a virtual resistance welding process on a computer The only difference from the actual welding process is that the whole process from design to welding is done on the computer without using actual materials and welding equipment Users will see the welding results virtually on the computer In this way the welding engineers can evaluate the weldability of materials design parts and electrodes and optimize process parameter settings before performing actual welding tests The procedure of making simulation with SORPAS is similar to the procedure of doing practical welding process which can be divided into the following three steps e Data preparation the materials and geometries of the workpieces and electrodes are defined the type of welding machine is selected and the process parameters are specified e Running simulation of welding the parts are welded in the selected welding machine with the specified process parameter settings The simulations can be carried out in four ways single simulations batch simulations automated optimizations and weld planning e Evaluation of results the results of welding and quality of weld are evaluated thus the design and parameter settings are verified With the optimization procedures the weld growth curve and the weldability lobes can be obtained With the newly implemented metallurgical and residual modules the microstructures and the hardness as well as r
52. S www swantec com 23 SORPAS User Manual 2 5 s1 s1_Gap 2force dat Version 10 6 The example s1 s1_Gap 2force is to illustrate how spot welding with a gap of 0 2 mm between the sheets before welding can be simulated The electrode is type B with conical shape and a tip face diameter of 6 mm In this example both electrodes are moving with equally controlled force The process parameters used for the simulation are shown in Table 6 and the report of simulation generated by SORPAS is shown in Fig 6 Table 6 Weld parameters for example s1 s _Gap Filename Squeeze time Weld time Hold time Current RMS Current Force type ms ms ms kA kN S Leap 40 160 120 8 4 AC 2 4 2force SOR9SS RSA T a Simulated with SORPAS R Version 10 1 Simulation finished Report of Simulation 01 03 2010 12 00 00 CASORPAS 10 1 Demo Workis1 s1_Gap 2force dat Spot welding 1 1mm steel 0 5 mm gap Computation time Number of Elements Materials Electrodes T 016 000 mm 016 000 mm Design of Weld Combination Type 80 a2 SO 5821 2009 Types SO 5821 2009 AISI 1008AW Nr 1 0338 Hr AISI 1008 W Nr 1 0338 Hr Process Parameter Settings Current kA Process time ms I rms 8 4 kA 50Hz Force kN Pmax 26 4 KVA E_wt 15683 0 mm Weld nugget size CC Molten 1 560E 03 1 4086 03
53. S R New Input Wizard Step 2 E SORPAS R New Input Wizard Step 2 x Select the Type of Welding Process Select the Type of Welding Process Spot welding Goto gt gt Weld Planning Spot welding Projection welding or other resistance welding processes so RO as Cancel sorgas Cancel Save Fj lt Back Go to Edit a b Fig 13 The Input Wizard step 2 to select the process to be simulated a Spot welding to continue with the Wizard for further data preparation or go to weld planning b Projection welding to switch to the general data editor more details described in Section 3 3 2011 SWANTEC Software and Engineering ApS www swantec com 31 SORPAS User Manual Version 10 6 Step 3 Define sheet combination As shown in Fig 14 the combination of sheets can be easily built up by giving the number of sheets and then the thickness and material of each sheet If the sheet is coated the thickness and material of the coating can be defined similarly The thickness of coating is given in microns or g m per side A coating layer is added automatically on both surfaces of the sheet A Gap between sheets can be added with a given size in mm either equally at all interfaces or with different sizes separately at individual interfaces Clamping in Y adds small tools at the edges of the sheets acting as static clamping in Y direction Fixing in X makes static clamping at the edges of the she
54. SORDAaS Version 10 6 User Manual SWANTEC Software and Engineering ApS March 2011 SORPAS User Manual Version 10 6 SORPAS is the professional welding software for Simulation and Optimization of Resistance Projection And Spot welding processes SORPAS is professional welding software specialized in resistance welding It has been designed for and used by engineers in industry including automotive steel making welding equipment electronics and other metal processing industries It has been used to support design and evaluation of the weldability of materials design and selection of electrodes as well as to directly support the optimization and planning of weld schedules with optimal welding process parameters With the functions for estimating the properties of welds after welding SORPAS has also been applied for quality assurance SORPAS is developed for engineers by engineers The user friendly graphic user interface with engineering language familiar to engineers has made it a very unique and powerful tool for applications in industry According to the practice of users a 1 2 days training has been sufficient for welding or design engineers to learn and start using SORPAS The special features of SORPAS can be summarized as follows Professional specialized and verified in resistance welding Straightforward designed and applied for industrial applications Easy to use develop
55. Settings Simulation Control yp Type of Geometric Model Type of Symmetry Line A ia Axisymmettic model Vertical symmety line x 0 ka hs Block model Model 1 of T symmetric division s z Elements 1000 Advanced View Mesh Generate Mesh Zz Delete Inset Size Move Merwe Obiect1 gt F Definition of the Current Object Electrode C Work piece C Coating C Interface Category Electrade materials z Material ISO 5182 A2 2 Electrode CuCiZr z we Initial T 20 000 C Geometry of Object gt gt 1 54750 9 5000 0 0000 a 2 6 0000 20 0000 0 0000 j te mii MoveP 3 s0000 20 0000 0 0000 E 4 8 0000 3 0000 0 0000 SJ 5 30000 0 1130 40 0000 Mesh Density Control Points 1 000 gt gt 0 000 1 035 9 000 a 12000 1 035 2000 x y mm density 1 0 9 0 0 000 22070 1 000 12000 22070 1 000 Defaut view AdancP lt ooo coon 1000 ji x m Tmm Fig 21 Input window for geometry and materials The interface layers are introduced to represent the contact properties at the interfaces The geometry of the interface layers is defined according to the geometry of the contact interfaces The thickness of the interface layer is determined by the roughness of the contacting surfaces and the thickness of the contaminant films which is usually in an order of 0 005 0 05 mm For large sc
56. The user can choose the weld current at a preferred percentage to the splash expulsion limit Users have also freedom to give preferred input values to other parameters for example to specify weld force weld time or number of pulse or simply let SORPAS to fully optimize by leaving the parameters at 0 c WSS Weld Schedule Specifications is the result of the Weld Planning with the optimized welding process parameters and the welding process window as well as the weld quality results simulated with the optimal welding process parameters v Multiple welds can be simulated now with continuous simulation of repetitive welding with the same electrodes but renewed sheets for every weld The Idle time is introduced after Off time with possibility for using a larger time step to speed up simulation of cooling between welds The heating and cooling history in electrodes is continuously accumulated through all welds v Many other updates for improved accuracy and graphic user interfaces 2011 SWANTEC Software and Engineering ApS www swantec com cai is SORPAS User Manual Version 10 6 Contents WHAT S NEW IN SORPASS 10 sccssccscscssssscsssssssessscsessssecssesesosooesneasss cossonsocesescseseeconsnsiocssssnsnssscosssassesssoosnsnstvoiees 2 BEFORE YOU START ss cssscasascssssesustssxctecsstste tesssatesaccsts casusstuta tedsnsestistacodsodecsvastecstsssedshsssccasctsssensoutasasaenbedtedearessntes 5 SYSTEM REQUIREMENTS scscs
57. User Manual Version 10 6 5 6 7 Input the initial temperature of the object in the Initial T box It is possible to specify initial temperature for every object individually for example a higher initial temperature for the electrodes etc The default value of the initial temperature of object is set to 20 C Define the squeezing out behavior of coating Click the button Coating a window is displayed for specifying whether to use the Automatic or Manual option As default the automatic option is chosen where the coating materials are assumed to be squeezed out starting at 80 of the melting temperature of the coating material and completing at 5 over the melting point Users may change the starting and completing temperatures for the squeezing out by selecting the manual option and giving new temperatures as seen in Fig 26 The melting temperature of the coating material is shown above the input boxes as reference Define Squeezing out of Coating xa The melting point of coating material 410 000 C Define squeezing out temperatures C Automatic Manual Squeezing out starting at 328 C completing at 430 C Fig 26 Window for defining the squeezing out of Coating Define the two ends of a thin layer by clicking Thin layer ends if the mesh of the thin layer coating or interface is not made properly with regular shape They are normally automatically identified by the program thus not necessary to do anyt
58. Wizard Step 6 z SORP 8 S GE Se Process Time Miliseconde Cycles Squeeze time Weldtime Hold ime Of time Idie time 2 000 foomo sooo faaooo fa o00 cycle Force Contro Loading Electrode Stepi H Noli afe Upper Slope Step Time Profile 7 000 po H Force 3000 H kN C pounds Sagi Force kN H 0 800 0 600 Current kA o areo seso 7520 sho H 0 300 Process time ms Fig 17 The Input Wizard step 6 to set the welding process time and the weld force 2011 SWANTEC Software and Engineering ApS www swantec com 35 SORPAS User Manual Version 10 6 Step 7 Define simulation and optimization procedures For a single simulation with the given welding parameter settings it is just a simple click on the Start button to run the simulation It is also possible to simulate multiple welds by giving the number of welds Further details on multiple welds are described in Section 3 3 5 The mesh has been automatically generated with high mesh density located in the weld zone It is possible to define automated optimization procedures for 1 optimization of the weld current such as prediction of the weld growth curve or optimizing the weld current to achieve a targeted weld nugget size 2 prediction of the weldability lobes to find the ranges of two welding parameters such as weld current and time or weld current and force 3 Weld plann
59. a C Axisymmetic model 7 Vertical symmetyine x 0 Pa m Block model Model 1 of 2 symmetric divisions z Elements 800 Advanced ViewMesh Generate Mesh Delete Inset Size Move Mere Obiect3 gt ni Definition of the Current Object C Electrode Work piece C Coating C Interface X Material AISI 1005 w Nr 1 0288 Hr CO 06 Mn0 35 v y Category Steel alloys ID 25 Initial T 20 000 C z Di Geometry of Object l T 0 0000 125500 0 0000 2 00000 10 5500 0 0000 e telu MoveP _ 3 25000 10 5500 0 0000 E 4 5 za 12 0000 10 5500 0 0000 12 0000 12 5500 0 0000 3rd Dimension Bulk thickness in Z 0 1000 mm End face inZ Mesh Density Control Points 10004 gt gt 0000 12600 9 000 B x y mm density 1 0 9 0 0O00 14 600 7 000 E 12 000 12 075 1 000 Defaut View adsocr c 2000 24850 1 000 Fig 32 The Block model for defining 3D geometries with the Cross Wire example 2011 SWANTEC Software and Engineering ApS www swantec com 50 SORPAS User Manual Version 10 6 Define End Face in the 3rd Dimension Z axis Types of End Face inZ i The end face defined below x Flat M Half inZ will be added in two halves z equally on each end of the flat Bulk thickness in Z x When Half inz la f Ball is checked only z one half of the
60. act Resistance Continue from Current Data File Continue from Current Data File Continue from Latest Simulated Data File Continue from Latest Simulated Data File Fig 50 Menu items of Optimization with active items for weld current optimizations Depending on the selected optimization procedure only one item on the Optimization menu will be activated Optimization of Weld Current will run simulations automatically to find the optimal weld current for the specified weld combination by estimating the simulated weld nugget size against the targeted weld nugget size Only the weld current in the data file will be modified with iterations while keeping all other data unchanged When the simulation is completed the optimal weld current is the one saved in the data file Generation of Weld Growth Curve will automatically prepare and run special batch simulations for generating the weld growth curve with the parameters as described in Section 3 3 6 When the parameters defining the weldability lobe is defined as described in Section 3 3 6 the corresponding menu item will be activated as shown in Fig 51 Clicking Generation of Weldability Lobe will automatically prepare and run special batch simulations for generating the weldability lobe Optimization of Weld Current Generation of Weld Growth Curve Generation of Weldability Lobe Verification of Contact Resistance Continue from Current Data File Continue from Latest Simulated Data
61. aees 28 2 10 1 S1_LOBE FORCE FIL WELDABILITY LOBE CURRENT FORCE ccccssssesescseseseseecesuesececeesenenenenanseaeaeeees 29 CHAPTER 3 USING SORPASS ii csssessssseceseesecsesseoossasravensecseseatocssesnsesestecsossauvaseasecdectesuddiaiecasedeesvestieveseseeses 30 3 1 INPUT WIZARD orat arere AEI utes tiiecirohast ale ne sie nen els eu edeens 30 3 2 WELD PLANNING AND WTD o 0 o o occcccccscsccccscsesesesecsesesessessssesesecsessesesessesssaesesasaeseseesassesececsesaeacecsesesaeerees 37 3 3 EDIT DATA FILE ccccccsssesesscscssesesesccsesesccssssssessscensssssesecssssssessseusessseessssssesessesesseescecssessacsecseseseeseseeaeesceenes 38 3 3 1 Define geometry and Maher ils ccc cccccccccc cece eesese ee seseeeceeseesesececsesseseeecsesseseeeseesseeeess 39 3 3 2 Define 3D geometries with the Block Model 00 cccccccecc cece ceeeseseeeeseeeecsesesseeseeseeseees 49 3 3 3 Specify machine setings 2 eee ceecccc aa a a Aa E 52 3 3 4 Define simulation control PArAMETELS 6 cccccccceceesssesce sees cesesecssescescsasesesesessaeatenees 57 3 3 5 Define process simulation for single weld or multiple welds 2001151001011512012 60 3 3 6 Define optimization procedures ccccccccccccscessssesscscessescusssecesesecstescesssssesicesesasenenaees 62 2011 SWANTEC Software and Engineering ApS www swantec com a3 SORPAS User Manual Version 10 6 3 4 PREFERENCES 2 0 25 ccvsiyis cehce
62. ale applications e g soot welding the 2011 SWANTEC Software and Engineering ApS www swantec com 39 SORPAS User Manual Version 10 6 contact layer thickness is usually set as 0 05 mm while for micro welding and projection welding the contact layer may be set as 0 01 mm The procedure for geometry design and material selection will be described below with the example s1 s1 dat In the tab Geometry and Materials the following data should be defined 1 In the Problem ID Name box the name of the problem Spot welding is written In the Note box the condition or note for the problem steel 1 mm steel 1 mm is written 2 The Type of Geometric Model can be axisymmetric or block model The axisymmetric model is for cylindrical geometry The block model is for geometries of 3D shape with a specified thickness or shape of end face in the third dimension Each object may be defined in different thickness or different shape of end face in Z this is referred to as 2 5D for treating the 3D problems Please refer to Section 3 3 2 for more details The example of spot welding is defined with axisymmetric model 3 The Symmetry Lines should be selected according to the geometry defined for simulations For axisymmetric problem only half of the geometry is needed for simulation thus a vertical symmetry line is used The vertical symmetry line is only allowed at x 0 and horizontal symmetry line at y 0 The geometry s
63. appears as shown in Fig 34 2 Select the welding machine to be used from the integrated Machine Database It is an option whether to limit the process parameters with the machine capabilities 2011 SWANTEC Software and Engineering ApS www swantec com 52 SORPAS User Manual Version 10 6 File E SORPAS s1 s1_watercool dat fe i SORPAS R Version 10 1 Enterprise Edition Reset Zoom Image SaveAs Save Undo Cancel ok S O RO 3 S itsss 2010 by SWANTEC Software and Engineering ApS All rights reserved Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help Problem ID name Spot welding 1 1 mm steel water cooled Geometry and Materials Machine Settings Simulation Control Machine 002 AC Arbitrary rocker arm spot welding machine v Process Time C Miliseconds Cycles Delete Insert Size Move Tool1 4 4 Geometry of the Current Tool Note JAC Limit to Machine ILmax 9 0 kA F max 4 9 kN Squeeze time Weldtime Holdtime Off time Idle time 2 000 fioooo f2o 0o00 f5o 000 fo oo0 cycle 01000 23 0700 ar 01000 22 0700 x y mm IE 81000 22 0700 r Tm kie vi L 81000 23 0700 a E Flow rate min Water T 0 i Mechanical Control Byforce C By velocity Free p 3 000 ao ao 0 000 bse p m T 13 333 0 000 3 000 8 699 p 2400 t ms Fx Fy kN j T sm 2 100
64. are and Engineering ApS www swantec com 74 SORPAS User Manual Version 10 6 Click the main menu item Animations in Fig 1 a list of eight items for displaying animations of variable distribution as shown in Fig 56 Animation of Temperature Distribution Animation of Temperature Rate Distribution Animation of Current Distribution Animation of Voltage Distribution Animation of Deformation Animation of Strain Distribution Animation of Strain Rate Distribution Animation of Stress Distribution Fig 56 Menu items of Results 3 6 1 Process parameter curves Process Parameter Curves are to display the simulated results of process related parameters with evolutions through the entire welding process including the voltage the current showing also the RMS value in the whole weld time the power showing also the total energy consumption the total resistance of the weld combination the volume of melted materials The weld nugget size the welding force on the moving tool the total displacement of the moving tool An example of the process parameter curve as function of welding time is shown in Fig 57 2011 SWANTEC Software and Engineering ApS www swantec com 75 SORPAS User Manual Version 10 6 ZE SORPAS s1 s1 dat CCIE File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help so GS SORPAS R Version 10 1 Enterprise Edition RO C
65. atabases Click main menu item Database in Fig 1 there are four active databases in the menu as shown in Fig 85 Material Database Electrode Database Workpiece Database Machine Database Fig 85 The menu items of Database The users can edit modify and add new items in the databases for material data geometries of electrodes and workpieces and machine properties 3 9 1 Material database Material properties are indispensable data for simulation There is a build in material database in SORPAS It is convenient for users to edit the material database modify it add new materials and load material data from other material database files Selecting the menu item Material Database under the Database menu as shown in Fig 85 the editor for material database is opened as shown in Fig 86 The materials are listed in different categories this makes it easier to search the materials It is possible to add new duplicate existing or remove categories and in each category to add new duplicate existing or remove materials The function Load Material from Database File is for transferring material data from other existing material database files Press on the button another material database file can be opened and the category and material lists are displayed as shown in Fig 87 Users can decide to load the selected category or only the selected material into the active material database of the system 20
66. ation control parameters appears as shown in Fig 36 2011 SWANTEC Software and Engineering ApS www swantec com 57 SORPAS User Manual SORPAS si s1_watercool dat Reset Zoom Image SaveAs Save Undo Cancel OK File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help Version 10 6 B Problem ID name Spot welding 1 1 mm steel water cooled Note AC Geometry and Materials Machine Settings Simulation Control Time step 0 500 0 200 1 000 1 000 10 000 ms Save data per 50 50 25 10 10 steps Models and Convergence Control I Electrical Model Converging accuracy 1 0E 5 I Thermal Metallurgical Model 1 0E 5 I Mechanical Model 1 0 5 T Elastic Loading 7 ThermalStresses Unloading Residuals Automated Optimization Procedures Process simulation Number of welds 1 Options Optimization of weld current Generation of weldability lobe Weld planning for optimal start weld schedule mm Verification of contact resistance to get nugget size gt Targeting weld nugget size Max Min C Sheet Object No Diameter C Height Vv Modify splash limit 0 gt Heat Loss to Surroundings Air Temperature 20 000 C Heat transfer rate 25 000 Contact Sliding C Sticking twin K sorRoas the 2 3
67. ave computation time usually a rather short squeeze time is used in simulations but the users should remember that the actual squeeze time might be much longer than the squeeze time used in the simulations 2011 SWANTEC Software and Engineering ApS www swantec com 53 lt SORPAS User Manual Version 10 6 4 The weld time is the time with current flow and heat generation It is corresponding to the actual weld time specified on the welding machine The hold time is the time needed for cooling the weld zone and solidification of the melted materials while electrodes still sitting on the workpieces The hold time can be determined by seeing all materials solidified or reached a state of solidification that has no more risk of separating the welded parts The off time is the time after electrode eject where cooling of the workpieces and electrodes continues separately It is usually the operation time of robots between welds in the production line The idle time is used when doing multiple welds simulation to help speed up simulation of cooling between the welds In the spot welding example the welding process time was defined by cycles where a squeeze time of 2 cycles a weld time of 10 cycles and a hold time of 8 cycles 50Hz are specified as described in Table 2 Insert the tools here tool implying the mounting of the electrode to the welding machine that conduct current from the machine to the electrodes and apply the
68. be displayed as shown in Fig 54 If it didn t start automatically it can be started manually by clicking the Start menu then Programs then SORPAS and clicking Watcher or double clicking the Watcher icon on the desktop 10 Watcher of SORPAS Simulation Progress o E aE 11 2 3 Watcher of SORPAS Simulation Progress o Data File s1 s1 dat Data File s1 s1 dat Process Time 62 600 ms Process Time 63 600 ms Welding Current 8 455 kA Welding Current 10 491 k Welding Force 3 000 kN Welding Force 3 000 kN Peak Temperature 1421 950 C Peak Temperature 1470 520 C Nugget Volume 0 011 mr Nugget Volume 0 009 mr Nugget Size 1 509 mm Nugget Size 1 265 mm Electrode Displacement 0 0571 mm Electrode Displacement 0 0580 mm 10 11 Simulation Progress B 0 10 47 Simulation Progress 0 11 19 Time Elapsed 0 01 10 Remaining 0 09 37 Time Elapsed 0 01 15 Remaining 0 10 04 2 3 Number of Welds 0 30 33 Total Elapsed 0 10 18 Remaining 0 20 15 Status Log 16 27 07 Weld time running a Status Log 16 37 45 Weld time running a 16 27 07 Squeeze time completed 16 37 45 Squeeze time completed 16 26 33 Squeeze time running 3 16 37 08 Squeeze time running 16 26 33 Simulation started 16 37 08 Weld no 2 3 Date 2010 04 15 v 16 37 07 Off time completed Sa Stop Simulation after Completing the Current Weld E Id Stop Simulation Close Wa
69. bility Lobe Active pulses to be optimized from No 1 tofi Range and increment of weld current RMS Min 4 000 Max 16 000 Increment 2 000 kA Skip simulations after 2 splash expulsion welds Select type of the weldiability lobe varying weld time of each pulse C varying weld force Min 4 000 Max 16 000 Increment 2 000 cycle Range of weld nugget diameter Min 3 500 Max 6 500 Nominal 6 000 mm Note The weldability lobe is generated according to the standard procedures recommended by 1S014327 2004 sornpas cme Fig 42 Control parameters for generation of the weldability lobe with varying weld current and time but constant weld force Each of the reference weld nugget size will show a line that will define the welding range The reference weld nugget sizes and the corresponding lines can be given with different values even after the simulations have been finished In the simulated weldability lobe the splash points and over sized weld nuggets are shown in red color the under sized weld nuggets are shown in black color whereas the points in 2011 SWANTEC Software and Engineering ApS www swantec com 64 SORPAS User Manual Version 10 6 between are shown in green color the likelinood of splash points are shown in yellow to orange color depending on the probability It is possible to read the weld nugget size at each point by moving the scroll bar on the control tool
70. blished and integrated in the system of SORPAS The material database includes mechanical and metallurgical properties of most commonly used materials The electrode database includes standard and user defined forms of electrodes The workpiece database is for frequently used product designs defined by users The machine database is for properties and capabilities of different welding machines With the Input Wizard and support of the databases SORPAS becomes much easier to use directly by engineers and more adequate for industrial applications 1 3 Applications of SORPAS SORPAS has been widely applied for evaluation of the weldability of materials and supporting design of products and electrodes as well as optimization of process parameter settings in various industrial sectors Before doing real welding tests the joint design and the welding process parameter settings can be tested and optimized already on a computer With this innovative method the develooment time and cost and the lead time to production can be significantly reduced The applications and benefits of SORPAS are summarized below 1 3 1 Evaluation of weldability of new materials and designs With the user friendly graphic user interface in SORPAS it is easy to draw geometries of workpieces and electrodes as well as to select materials for each 2011 SWANTEC Software and Engineering ApS www swantec com 14 SORPAS User Manual Version 10 6 part of t
71. by force To show how to simulate spot welding with gap between the sheets before welding 2011 SWANTEC Software and Engineering ApS www swantec com 17 SORPAS User Manual Version 10 6 DP TRIP_ watercool dat File gt Open Data File Spot welding of 1 5 mm DP600 to 1 2mm TRIP700 steel sheets with water cooling in the electrodes To show how to simulate with water cooling in electrodes and to demonstrate the metallurgical and residuals results Cross Wire dat File gt Open Data File Cross wire welding with diameters of 2 mm applying the 2 5D block model To show how to simulate 3D geometries with the 2 5D treatment in SORPAS s1 s1_growth File gt Weld growth curve for To show the predicted curve Fil Open Batch spot welding of two 1 weld growth curve File mm mild steel sheets s1 s1_lobe time fil File gt Weldability lobe with To show the predicted Open Batch varying weld current weldability lobe File and time and constant force for spot welding of two 1 mm mild steel sheets s1 s1_lobe force fil File gt Weldability lobe with To show the predicted Open Batch varying weld current weldability lobe File and force and constant time for spot welding of two 1 mm mild steel sheets In order to understand how SORPAS works it is recommended that new users shall first view the examples to get familiar with the main functions of the software
72. cceescccscecssccesssessesscceessesseecssecssscsssecssecsacceesecssecsuscessesssecsuccesscesssecssecescessecssecsuseesseeeaes 98 3 9 1 Material Data se oo cece ccccccccccccccscsssscsecssussessusseesesvssseusssssssssesssscsasescsacsecsseascsesasescnaees 98 3 9 2 EIECHODS AGIOD ASE iurien a leased a a E laos es 101 3 9 3 Workpiece database secccssiiniicecsiunnii niiin aaa N E SEE EREE 105 3 9 4 MACHINE database ucenicii E NE E ENEE ER 107 3 10 OTHER FUNCTIONS 0 cccccccccceccesccssecssesscescsecosccsseseceuecesecssesscuascssecssssusseseascssecsesssseascssecsusssseaecsacsaesseees 109 310 1 VIEW aierratanaknanina nd be EA bad aa a a a Aa a a e Ae 109 Bc T02 aa e E NEEE EA E E E A S 110 CHAPTER 4 ERROR MESSAGES wssssscsssssscssssessccssssssesssconscsssosscosscsssesesnsacsnsscssecensucosbebictsusssceboetscssusesesiacsees es 111 4 1 ERRORS RELATED TO DATA FILES 0 ccccesccesecsseescesecoseseecesesscesccosssesesecssecsessesesscescsuecaevessesecnsecseseseesenseees 111 4 2 ERRORS RELATED TO INPUT DATA AND MESH GENERATION 0 ccccccsceseescseeecosescssveccesesecesaesecssvessasesecaneas 111 4 3 RUN TIME ERRORS c ccccccccccsesscssecssecsccsecescesecoseceseescesecssesssesucuaecsucsaecsseseseaecsaecsesseseascnsecseseusesceasessesseees AA REMARKS orse rasaire eR eraa A A aer AO A NEA NEAN ARAE NETRE EAA AIENEA ANEA APPENDIX END FACE IN Z FOR BLOCK MODEL 2011 SWANTEC Software and Engineering ApS www swantec com
73. csssscssscscscscsesesesesesesessssssesesevavssssacsesesesesesssasssaesesesesesassssesesesavasscasseeesesenesavseseseaees 5 INSTALLATION OF SORPASS prian aaneen e aaa AE A EA AE E EEA ARAE AE E AEE A ERA 5 EDITIONS OF SORPAS o oo cccccssssssssscsesesesesecescsessvsvsesesesesesesesessssssesesavssasecasacsesesssavssasaesesesesesecacseseseaceeseseeeeaes 6 ADD ON MODULES 55535503500 cs svccsesezscealansanscusganssahe esast AEKA ERA S EEAS A aE E AAAS ERSE EREA AREAS PEIR AAPEEE Ii 8 STARTING SORPASSO E E AOTT A TET ETE TETEE AATE TE 9 CHAPTER 1 INTRODUCTION sissssssssosssvosconsssnsnsecarssssoasnsivesnsesovesesoasneasonnsesasenssdesasbonansesacenssensnsesorsaesoesnedshoniyed 11 Vd WHAT AS FEM EE E E EE E 11 EET M sh densi rocnirniign ean e a nEaN NAE E E ENON E 11 LZ TMe Stepio ENEE OT EEA A 12 1 2 HOW TO MAKE SIMULATIONS WITH SORPAS 0 0 cccccsssseseseseseseseeccecesesesesesesesesesecscsesssesevavsesesescseseseseeaes 13 1 3 APPLICATIONS OF SORPAS 0 cccccscscsssesssscecscscscsesesesesesesesesssscsesesevavavssesesesesesesavassesesesesesececseseseseseeaes 14 1 3 1 Evaluation of weldability of new materials ANd AeSIQNS ccccccceceteteeeetete teens 14 1 3 2 Optimization of process parameter settings c ccc cccceeteseceeseteeecsesesetecsesenseseeesas 15 1 3 3 Prediction of the weld quality and properties after welding 2 0 00000010101100101010 15 1 3 4 Production MAINFENANCE 0
74. density scale from 1 to 9 Higher density scale means higher density or smaller size of elements Pressing Default button the default density control points will be generated automatically where several low density points locate at the top and bottom and some high density points near the weld zone Users may move a density control point by changing its coordinates or delete any density control point if necessary It is also possible to add more density control points into the list Clicking on Add DCP the mouse enhanced function for adding density control points is activated First set the density scale and then Left Clicking at the positions to add density control points Right clicking will finish the operation Fig 28 shows the activities for adding density control points It can be seen that the high density points are located in the middle of the weld zone density scale 9 while the low density points are located at the end of the steel sheets density scale 2 and other places in the geometry density scale 1 2011 SWANTEC Software and Engineering ApS www swantec com 46 SORPAS User Manual Version 10 6 SORPAS st sl da File Input Mesh Simulation Batch Run Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help TEETE 2 es ees es SORPASS ER a Eog Aot Aria reread Problem ID name Spot welding Note steel 1 mm steel 1 mm 1 000 1 000 1 000 Geometry and Materials
75. des will be used again and again in many different simulations therefore an electrode database is included in the program The electrode database includes all the spot welding electrodes recommended in ISO 5821 It is also open for the user to add new electrode design or modify electrode design already included Click Database menu in Fig 1 and then select Electrode Database The editor for the electrode database is shown in Fig 88 The Electrode List is a dropdown list for all the electrode design in the database Users may select any one to display the electrode design data The name of the current electrode can be entered with the edit box below the electrode list Selection of the electrode can also be done with the Scroll Bar The number on the left side of the scroll bar is the ID number of the current electrode displayed The number on the right side is the total number of electrodes in the database It is possible to add new duplicate existing and remove electrodes The buttons for editing the electrode list are described below e Duplicate button is to add a new electrode at the end of the electrode list with the same design as the selected electrode e Add New button is to add a new electrode at the end of the electrode list with no design listed e Remove button is to delete the selected electrode from the database Load Electrode from Database is for loading electrode design from another electrode database into the current one It
76. dit box with the x and y coordinates of the contour points and the radius of curvature r The points are defined in the counter clockwise direction If the direction is wrong ERR will be displayed in the graph The workpiece is highlighted in yellow color with red lines on the border in the graphics window The coordinates for the contour points shown in the list window can after selection be modified in the edit box The selected point is shown as a red dot in the graphics window 2011 SWANTEC Software and Engineering ApS www swantec com 105 SORPAS User Manual Version 10 6 Button gt gt is to insert point co ordinates below the selected point or otherwise to the end of the list lt lt is to remove the selected point and is to modify the selected point A round corner may be defined by giving the radius of the corner to the starting point connecting to the next point It is obvious that the radius should be larger than a half of the distance between the two points A positive radius defines a convex round corner while a negative radius defines a concave round corner In order to avoid confusion in the orientation an exact half circle should be defined by two pieces of arcs with a middle point Similar to electrode database functions are added for supporting storage of multiple objects in the workpiece database see Fig 90 Five general operational buttons are located in the upper right corner
77. e Button Zoom is to zoom in or out the display area and move the graph by using the control tool shown in Fig 31 Button Reset is to resume the graphical display fitting the window Button In is to enlarge the graph and Out is to shrink the graph Buttons Up Down Left and Right are to move the graph Button gt gt is for fast zooming and moving and gt is for slow zooming The vertical scroll bar on the left is for zooming in by going down or zooming out by going up The horizontal scroll bar is for moving the object horizontally and the vertical scroll bar on the right is for moving the object vertically The button Click 2 Points in the Zoom window is to activate the mouse enhanced zoom function The zoom area can be defined by clicking 2 points crossing the desired area with whichever order The two corner points of the zoom area after correction to the aspect ratio are displayed in the edit window bar The two points can be modified and then with the Set Zoom function the zoom area can be set manually This makes it possible to define exactly the same zoom by copying the coordinates of the zoom area corner points from one example to another The width and height of the display area are given by dx and dy Zoom Control m Down Out a i E Click 2 Points SetZoom xl y1 x2 y2 a 6 913 23 204 28 813 25 274 dx 45 727 dy 48 477 Fig 31 Control fool for zooming and moving of
78. e entered with the edit box below the category list or the material list An edit box and a list window are designed for inputting the data of each material property The button gt gt is to add the data in the edit box into the list the button is to replace the selected data in the list with the data in the edit box whereas the button lt lt is fo remove the selected data from the list Thermal conductivity heat capacity mass density and resistivity are defined as functions of temperature The temperature and the corresponding value of the property are typed in the same time separated by a comma or a space 2011 SWANTEC Software and Engineering ApS www swantec com 100 SORPAS User Manual Version 10 6 The surface contaminants resistivity of the material is used for calculating the contact resistance between materials during simulations which is now associated with each material As a general rule when two different materials come into contact during welding simulation the lower value of the surface resistivity of the two materials will be used as the contact resistivity at the interface The flow stress is defined as a function of temperature strain and strain rate with the following expression at each temperature o C Bt e Where os is the flow stress C isthe material constant Bis the pre strain for work hardened material isthe true strain n isthe strain hardening exponent
79. e shape of the object the Position to insert must be selected The object can be inserted On Top or Under Bottom of the existing objects or At Position defined by x and y coordinates in mm the position refers always to the lower left corner of the new object Inserting mE Select Object to Insert Duplicate the Current Object C Sheet Rectangle W y H mm Thin Layer W H imm C Workpiece Database Plate 1 Omm C Electrode Database Type AO di 13 R1 30 IS0 v C New From Text File List of xyr Select Position to Insert OnTop C Under Bottom C At Position x va mm so RO as Cancel Fig 22 Input window for inserting new objects The two steel sheets in the example are inserted as Sheets with a width W of 12 mm and thickness H of 1 mm The electrodes are inserted as ISO 5821 Type BO with a conical tip diameter of 6 mm selected from the Electrode Database The interface layers are inserted as Thin Layers with a width of 12 mm and thickness of 0 05 mm ll The geometry of the object can be defined or modified in the box for Definition of the current object with the x and y coordinates of the contour points and the radius of curvature r for each contour line The points must 2011 SWANTEC Software and Engineering ApS www swantec com 41 SORPAS User Manual Version 10 6 be defined successively in the counter clockwise direction if the direction is wrong ERR
80. ed The input data editor for preparing and editing simulation data can be opened by clicking the menu item Input and then clicking Edit Data File A dialog window for input data of geometry and materials will appear as seen in Fig 21 2011 SWANTEC Software and Engineering ApS www swantec com 38 SORPAS User Manual Version 10 6 Three groups of input data need to be prepared 1 geometry and materials 2 machine settings and 3 simulation control parameters The example s1 s1 dat is going to be used to explain the details Information related to the example is written in Italic 3 3 1 Define geometry and materials The geometry and materials to be defined include the workpieces the electrodes the coatings and the contact interface layers between the workpieces and between the workpiece and the electrode The geometries of the workpieces and electrodes are defined according to the design of weld parts and electrodes ZE SORPAS s1 sl dat co amp ils File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help SORPAS R Version 10 1 Enterprise Edition Reset Zoom Image SaveAs Save Undo Cancel OK sorRogas 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved Problem ID name Spot welding 1 Note steel 1 mm steel 1 mm Geometry and Materials Machine
81. ed the material database will automatically be activated with the default material defined in Preferences after that different categories and name of materials can be selected from the integrated material database The Interface is introduced as an artificial layer between the loosely contacting surfaces to represent the contact properties The contact resistance is calculated by the following model O soft P contact 5 7 2 2 a F Taans n where os soft is the flow stress of the softer metal of the two in contact on is the contact normal pressure at the interface pis the resistivity with subscripts 1 and 2 indicating the two base metals in contact Peontaminants is the surface contaminants resistivity due to oxides oil water vapor and dirt etc This value is included in the material database as described in Section 3 9 1 y is a factor introduced for adjustment and verification of the contact resistance 2011 SWANTEC Software and Engineering ApS www swantec com 42 SORPAS User Manual Version 10 6 When Interface is selected the scaling slider for adjusting the contact resistance dirty clean factor is activated with a default value of 1 0 implying directly taking the values of the surface contaminants resistivity from the material database It can be changed between 0 1 and 10 0 according to the surface conditions of the materials in contact When calculating the contact resistance this factor will be multiplied
82. ed by SORPAS is shown in Fig 5 Table 5 Weld parameters for example s1 s1_Gap Iforce Filename Squeeze time Weld time Hold time Current RMS Current Force type ms ms ms kA kN s1 s1_Gap 40 160 120 8 6 AC 2 4 lforce SORGSS S253 ee ee Simulated with SORPAS R Version 10 1 Simulation finished Report of Simulation 01 03 2010 12 00 00 C SORPAS 10 1 Demo Workis1 s1_Gap tforce dat Spot welding 1 1mm steel 0 5 mm gap Computation time Number of Elements Materials Electrodes T 016 000 mm 218 000 mm Design of Weld Combination Type B0 a2 SO 5821 2009 Types SO 5821 2009 AISI 1008AW Nr 1 0338 Hr AISI 1008 W Nr 1 0338 Hr Process Parameter Settings 0 000 aon 4 sos J Current kA 9 124 ai I rms 8 6 kA 50Hz Process time ms Force kN Plmax 265 KVA E_wt 16222 mm Weld nugget size CC Molten 1 560E 03 1 408E 03 1 2526 03 1 098 03 9 4408 02 7 S00E 02 6 360 02 4 8206 02 3 280 02 1 7408 02 2 000 01 Simulation Result Temperature Distribution and Weld Nugget Nugget Size at Interface A B D 5404 mm Fig 5 The report of simulation generated by SORPAS for example sl s1_Gap 1force the upper part is the welding conditions and the lower part is fhe main simulation results 2011 SWANTEC Software and Engineering Ap
83. ed for engineers directly to use in industry 2011 SWANTEC Software and Engineering ApS www swantec com 215 SORPAS User Manual Version 10 6 What s new in SORPAS 10 With this new version all models and functions in the entire system of SORPAS have been thoroughly tested and improved based on many valuable feedbacks and requirements from users as well as our own tests and verifications All known issues have been corrected Many new functions have been developed and implemented For example the new landmark Weld Planning function can automatically predict the fully optimized weld schedule specifications WSS including optimized weld current weld force weld time and hold time simply according to user defined Weld Task Description WTD defining only the sheets electrodes type of weld machine and the desired weld quality The key new updates comparing to previously released SORPAS 9 0 are described below v Weld Planning to predict the optimized weld force time and current with the process window see figure above a WTD Weld Task Description is the new input window for specifying a weld task As the purpose of the Weld Planning is to find the optimal welding process parameters the WTD will only need information about the sheets electrodes type of welding machine and the desired weld quality b User preferences is for user preferred planning strategy The welding process window will be predicted by SORPAS
84. eda E File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help S O ROQ 3 S SORFAS R Version 10 1 Enterprise Edition i C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved Austenite fraction 1 000 0 900 0 800 0 700 0 600 0 500 0 400 0 300 0 200 0 100 Proc time 1 740 s Max Aus 2 0 000 Aus 236 1 000 Aus 253 1 000 Min Aus 2 0 000 Aus 236 0 000 Aus 253 0 000 ISO 5182 A2 2Elec DP 600 SAE 32340 6 TRIP 700 H400T Timm 0 000 Fig 79 Distribution of volume fraction of austenization 2011 SWANTEC Software and Engineering ApS www swantec com 93 SORPAS User Manual Version 10 6 3 7 5 Distribution of Volume Fraction of Martensite Formation The martensite formation has been modeled according to the austenization the martensite start and finish temperatures and the critical cooling rate for martensite start and full formation The martensite start and finish temperatures are dependent on the chemical composition of the steel There are numerous formulas can be used to calculate these characteristic temperatures The critical cooling rates can be obtained from the CCT diagram of the steel Fig 80 shows an example of the volume fraction of the martensite formation ZE SORPAS DP TRIP_watercool dat ec ee File Input Mesh Simulation BatchRun Optimization Weld Plan
85. eeeeseneees 81 3 6 6 Report OF SHMUTATION 2 0 2 ccc cccccccecsssesesscssusssecsssesssssecsesaseecssseessssecsasessssesecsseasesesaseaesaees 82 3 6 7 Final Temperature Distribution and Weld ReSUITS 0 cc ccccccccccescesescesescsseeessseseesees 82 3 6 8 AMiMaAtiONS 200 0 ccccccccec ccc cecesccesseescsecececeseescesecascessesscesceascaseessseseeaecuscssesssesscnsessstseeseeseens 3 7 DISPLAY METALLURGY RESULTS cccccccccsscsseseesees 3 7 1 Distribution Of Peak Temperature 0 cc ccc cs cescscssessssescesesesesesecssesscscssseesssesesseeatsaees 3 7 2 Distribution of Cooling Rate at 700 C 3 7 3 Distribution of Cooling Time from 800 C to 500 C 3 7 4 Distribution of Volume Fraction of Austenization 0 00 00cccccccccccceceeceeseesceseeeseeseeseens 3 7 5 Distribution of Volume Fraction of Martensite Formation 00 00 cccccccccc cece eeeseeeeee 94 3 7 6 Distribution Of HALANESS ccc cee ccccccceeccesc coc ceceesseesceseceeeessesscesececcsseesessseascssessseerenssesees 95 3 8 DISPLAY THE RESULTS OF RESIDUALS c ccccccscccscescesccssecsscscesscesecssecsssescesscssecsssescesscsscsuecssesssesscsuecseseneease 95 3 8 1 Distribution of Residual Stresses oo ccc cece cee cecceeeesseesceseceeccsseesceascsesseeeseeseeseensees 96 3 8 2 Distribution Of Cracking RISKS cccccccccccssesssscssssececsssseseeceessesesececsessssecsessnecseaeseeeas 96 3 9 DATABASES 0 cccccc
86. een implemented to take into account the different conditions and properties of individual welding machines in order to make more realistic simulations for practical welding processes The machine database includes capabilities of the welding machine or gun such as the maximum limits of weld current power and force the type of power source and the electrical and mechanical characteristics of the machine system Some data are not yet used in the current version The types of power source including AC DC and Capacitor Discharge CD have been moved to the machine database as they are associated with each individual machine The power source type appears in the name of the machine as a prefix 2011 SWANTEC Software and Engineering ApS www swantec com 107 SORPAS User Manual Version 10 6 The conduction angle with AC machine is defined as a function of r m s current in the database in a similar way as it works in the actual machine It can be set either in Percentage or in Degree When preparing data for simulations the conduction angle will be automatically calculated from the functions in the Machine Database corresponding to the given r m s Current The maximum capabilities have been introduced to make sure that the welding process runs within the limits of the actual welding machine Users can choose as an option during preparation of simulation data whether to use the machine limits or not Machine Database Save Canc
87. el OK Remove Add New Duplicate 6 No2 af gt Machine List 002 AC Arbitrary rocker arm spot welding machine Machine Name Arbitrary rocker arm spat welding machine Power Source ac DC Capacitor Discharge Capabilities of the Machine Imax 9 000 kA P max 28 000 kVA F max 4 900 kN Weld time range gt tmin 1 000 cycle tmax 30 000 cycle Electrical Properties of the Machine System 0 000 0 000 0 000 Conduction Angle vs IAMS 4 000 50 000 HH 6 000 60 000 lms kA Cond Angle 8 000 80 000 8 800 95 000 Cwm CC lt lt Mechanical Properties of the Machine System 0 000 0 000 0 000 Vimax 30 000 mm s A max 2000 001 mm s 0 000 Fig 91 Editor for machine database For the mechanical dynamic properties of the machine two parameters are currently functioning namely the Vel max and Acc max The Vel max parameter is the maximum follow up velocity and the Acc max parameter is the maximum acceleration of the moving electrode depending on the mechanical 2011 SWANTEC Software and Engineering ApS www swantec com 108 SORPAS User Manual Version 10 6 characteristics of the welding machine They are introduced to consider the follow up behavior of the electrode in case of collapse of materials especially in projection welding According to testing of some welding machines the max velocity is usually b
88. er defined range of weld current from a lower limit to a higher limit with a given increment whereby the weld growth curve will be generated The other one is for automatically running simulations to seek for the optimal weld current according to a targeted objective weld nugget size Automated generation of weldability lobe two types of the weldability lobes can be generated automatically following the procedures recommended in ISO 14327 2004 where two process parameters are varied One type is to vary the weld current and time while keep weld force 2011 SWANTEC Software and Engineering ApS www swantec com 7 SORPAS User Manual Version 10 6 constant The other type is to vary the weld current and force while keep the weld time constant The splash limits are predicted and the weld ranges are indicated according to three reference weld nugget sizes minimum nugget diameter maximum nugget diameter and minimum nugget height penetration in the thinnest outer sheet which are given by the users Automated weld planning This new function can automatically predict the optimal weld schedule specifications WSS including optimal weld current weld force weld time and hold time simply according to user defined Weld Task Description WTD defining only the sheets electrodes type of weld machine and the desired weld quality Add on Modules Two add on modules including the Metallurgical module for prediction of martensite and hardne
89. erature and the heat transfer rate of air is required as shown at the bottom in Fig 36 3 3 5 Define process simulation for single weld or multiple welds As shown in Fig 36 with the selection for Process simulation one can simulate the entire welding process of a single weld by setting the number of welds at 1 Increasing the number of welds beyond 1 will automatically set the simulation to run with multiple welds The simulation of multiple welds allows the user to make continuous simulation of repetitive welding for a number of welds with the same electrodes Clicking the button Option activates the window as seen in Fig 38 There are currently two options available The first option uses the same materials and sheets but un welded new sheets each time starting a new weld this is similar to an industrial welding line The second option uses the same sheet repeating the weld at the same spot which acts as a re weld Other options are still under develooment and may be available in future versions 2011 SWANTEC Software and Engineering ApS www swantec com 60 SORPAS User Manual Version 10 6 Note To continue multiple welds with the same electrodes Select sheets for each new weld C Same sheets and repeat welding at the same position again Same shee t aw positior soli Model electrode changes T Electrode geome anges a ion of number of we E f Step current r soRpaS
90. esidual stresses and cracking risks in the welds can be predicted The input data for preparation of simulation with SORPAS can be summarized as below 1 Geometry and materials o Define geometry and select materials of workpieces o Define thickness and select materials of coatings o Define forms and select materials of electrodes o Define contact interfaces between materials for spot welding this is automatically done with Input Wizard 2 Machine settings o Define mounting of electrodes or connection of electrode to machine o Select welding machine 2011 SWANTEC Software and Engineering ApS www swantec com 13 SORPAS User Manual Version 10 6 o Define water cooling parameters o Set welding process parameters 3 Simulation control o Define time step and interval for saving result files o Select numerical models and define accuracy of each model o Set optimization procedures weld growth curves weldability lobes etc After all the input data are prepared the simulation can be started simply by clicking a button The simulation will then run automatically The results will be saved along with the progress of simulation which will be used later for analysis and graphical display including the process parameter curves animations for the dynamic development of weld nugget and temperature distribution in the materials etc In order to facilitate industrial applications of SORPAS four databases have been esta
91. ess in Z equals O for standard cone or has a bulk thickness combined with the cone end face b The radii of the bottom R1 and the top R2 of the cone c The coordinates of a point on the central axis of the cone d The angle of the central axis of the cone from bottom to top with respect to x axis 5 Wedge end face which is defined by a The bulk thickness in Z equals O for standard wedge or has a bulk block of the given thickness combined with the wedge end face b The angle of the central axis of the wedge from bottom to top with respect to x axis c The bottom length of the wedge end face as illustrated in Fig 33 The ending shape of the object in Z is defined with the end face in Z which is added in two halves equally to each end of the flat Bulk thickness in Z When Half in Z is checked only one half of the ending shape defined by the End Face in Z will be added to the Bulk thickness in Z The bulk thickness in Z is not influenced by the activation of Half in Z Some examples are provided in the Appendix for illustrations of how to define the Block Models with End Face in Z 3 3 3 Specify machine settings After defining the geometry and materials the welding process parameters or the Machine Settings need to be specified The welding parameters for the spot welding example are defined in Table 2 1 In Fig 21 choose the tab Machine Settings The dialog window for input of machine settings and process parameters
92. ets in X direction Un checking one will allow free movement in respective direction The weld stack combination of materials are built up automatically with interface layers inserted between the sheets which represent the contact properties 3 SORPAS st si dat o a File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help r SORPAS R Ve ic 410 1 Enterprise Editio SORPAS R New Input Wizard Step 3 3 so RO as sss 2m0 by SWANTEC Solarcasdaphaeatng ApS All rights reserved How mary sheets tobe welded 2 A Sheet No 1 Dimension and material of each sheet 5 Thickness mm Thickness per side um Width mm Sheet 1 000 H Coating 0 0 1200 H um C g All sheets Gap between sheets mm 00 H Sheet material IT Fixing in I ClampinginY Category Steel alloys x Material AISI 1005 W Nr 1 0288 Hr C0 06 Mn0 35 z Coating material Category z Material x sornoas Cancel Save lt Back Next gt es ee mm Fig 14 The Input Wizard step 3 to define the weld combination of sheets 2011 SWANTEC Software and Engineering ApS www swantec com 32 SORPAS User Manual Version 10 6 Step 4 Define electrodes As shown in Fig 15 the electrode design can be selected from the database of electrodes and its material can be selected from the database of materials More detai
93. etween 10 100 mm s during welding and the default value of Vel max is set to 30 mm s The max acceleration is usually between 1000 100000 mm s and the default value of Ace max is set to 2000 mm s 3 10 Other Functions There are two more menu items in Fig 1 for other functions 3 10 1 View The menu item View in Fig 1 includes eight items as shown in Fig 92 Clear Screen is to clear the display window Save Image As is to save the displayed graph in bitmap picture Zoom is for Zooming and moving the graph Mesh Nodal Number is for display the mesh and clicking twice for nodal numbers Isotherm line is for displaying the isotherm line heat affected zone or the temperatures at two nodal points Fill in Nugget Outline is for display the weld nugget in solid filling with only contour line or no nugget outline Show Weld Nugget Sizes is to write the final weld nugget sizes on the graph Show Splash is for showing the graphical indication of splashes expulsions Set Scale is for user defined scale limits for the color spectrum used for distribution of parameters or for current and force in Report of Simulation Click on Show Full in Symmetry will switch between full and half display of the symmetric geometry Hide Electrodes will only display the distribution of results in workpieces Hide Workpieces will only display the distribution of results in electrodes 2011 SWANTEC Software and Engineering ApS www swantec com 109 SORP
94. example of the second type of weldability lobe as described in Section 2 10 3 6 5 WSS Weld Schedule Specifications The results of the Weld Planning are shown in the Weld Planning Report with the optimal Weld Schedule Specifications WSS Fig 65 shows an example of the Weld Planning Report which includes four parts 1 The upper left quarter is the weld task description WTD with information of the sheets electrodes and type of welding machine 2 The upper right quarter is the graphical display of the optimal welding process parameters 3 the lower left quarter is the Weld Schedule Specifications WSS with the optimal weld current 2011 SWANTEC Software and Engineering ApS www swantec com 81 SORPAS User Manual Version 10 6 foce weld time and hold time together with the welding process window with predicted splash limits 4 the lower right quarter with the welding results obtained with the optimal welding process parameters Based on the proposed optimal welding process parameters users can quickly pick up the starting welding parameters BE SORPAS s1 s1 dat a File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help so BS SORPAS R Version 10 1 Enterprise Edition RO C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved Simulated with SORPAS R Version 10 1 Simulation finished 01 03 2010 12 00 00 Weld
95. he pulse numbers from to If the levels of weld current are different in different pulses SORPAS will keep the ratio of the weld current levels unchanged during the optimizations The weld current of the pulse number given by Ref will be used as reference during the optimizations User Preferred Parameters for WSS xa Electrode Force 0 000 kN kN pounds Number of Pulses f2 from j to 2 Ref ji Weld Time of Each Pulse 0 cycles C ms Cycles Note Zero value for a parameter above means it will be optimized by SORPAS R Non zero value given to a parameter above will be used as fixed input value Minus value in Weld Time means to use User defined Weld Timefs in data file Weld current will always be optimized by SORPAS R sorngas Cancel Fig 20 User Preferred Parameters for WSS 3 3 Edit data file The data file can be opened as follows Click the menu item File then click Open Data File the Open Data File dialog box appears similar to all standard Windows programs browse to the folder Work in the main folder of SORPAS then choose for example the s1 sl dat file and then press Open When the data file is correctly opened the input data editor window will be displayed for new data file or the final temperature distribution will be displayed if the simulation results had been generated before or otherwise the mesh will be displayed if mesh was already generat
96. he weld combination from the integrated material database This makes the evaluations of different designs and weldability of new materials much easier For example spot welding of multiple sheets with different materials and complex thickness Combinations can be easily simulated where the optimal weld current can also be predicted The design of joints in projection welding can be evaluated and tested with simulations before real welding tests By making simulations with different forms of electrodes the optimal electrode form can be determined according to the results of welding simulations By making simulations with different materials of the electrodes the optimal material of electrode can be determined The same evaluations and optimizations can be made for surface coatings 1 3 2 Optimization of process parameter settings A tedious job of welding engineers doing everyday is to optimize the process parameter settings for every specific weld combination In many cases the design and materials of the joints have been decided by preceding production stages for example stamping This leaves the welding engineers only the possibilities for selecting the form and material of the electrodes and optimizing the welding process parameters With support of SORPAS the process parameter settings can be optimized by running simulations with the automated procedures In SORPAS there types of the parameter optimizations can be automatically carried
97. hing about this until the mesh in the thin layer is seen not made in regular shapes a regular shape should have corners in nearly right angle Users can then manually define the two ends of the thin layer by giving the corner point numbers at the starting of each end line which will help to make the mesh in the thin layer regular see Fig 27 Define the end points of thin layer First end at corner No Second end at comer No Cancel Fig 27 Window for defining the corner points at the ends of thin layer 2011 SWANTEC Software and Engineering ApS www swantec com 45 SORPAS User Manual Version 10 6 8 9 The total number of Elements needs to be specified by users The default number is defined in the Preferences for example 500 of each sheet In general the accuracy of simulation can be increased with increasing number of elements but the computation time will also increase The optimal number of elements can be found by trying several simulations of the same example with increasing number of elements for example 500 1000 and 2000 with 5000 as maximal If the results of simulation will not change much with an increased number of elements then the smaller number can be chosen as the optimal number of elements The mesh in the spot welding example is specified to 1000 elements The density distribution of the mesh is specified by the density control points DCP defined by the co ordinates x and y and the
98. hod FEM is used in SORPAS for the numerical simulations The FEM is a numerical method widely applied for engineering analysis The main idea of FEM is that a complex engineering problem can be solved by dividing into a number of simple pieces or elements When the problem is solved in each piece or element the solution of the entire problem can be obtained by an assemblage of all pieces or elements Due to this universal procedure FEM can be used to solve nearly all kinds of engineering problems with very complex geometry and material combinations After many years research and development according to industrial applications all numerical procedures have been developed and fully automated in the system of SORPAS The user interface of SORPAS is designed with professional language and engineering expertise in resistance welding Due to this many users have started using SORPAS without prior knowledge of the FEM Most of users are welding engineers working in industry It is always helpful to get some basic knowledge of the FEM in order to better understand the software and to make more reliable simulations More detailed fundamental knowledge of the FEM will be introduced at the training course we hereby emphasize two basic concepts that have essential influence on simulations 1 1 1 Mesh density The mesh density or the size of elements has essential influence on the accuracy of FEM calculations regarding to distribution of variable
99. hould be placed on the positive side of the symmetry line 4 Insert and define the geometry of all objects including electrodes workpieces coatings and contact interfaces The contact interface layer should be inserted as an object to represent the contact properties at the interface The procedure for defining the geometry and materials of each object is as follows Click the Insert button to open the Inserting window see Fig 22 The highlighted object can be duplicated New objects can be inserted as a Duplicate the Current Object highlighted in yellow color as a Sheet Rectangle defined by a width and a height as a Thin Layer defined by a width and a height as loading from the Workpiece Database as an object loading from the Electrode Database as a New object or load an object From Text File 2011 SWANTEC Software and Engineering ApS www swantec com 40 SORPAS User Manual Version 10 6 The Electrode Database and the Workpiece Database are connected respectively to the integrated databases of workpieces and electrodes to select pre defined designs More details are described in Sections 3 9 2 and 3 9 3 The New inserts an object with only a starting point that can be extended into any shape For inserting a new object From Text File the text file shall be written in text format with a list of corner points at each line with the values of x y and the round corner radius r After choosing th
100. ial T 20 000 C Di Geometry of Object 1 5 4750 9 5000 0 0000 4 2 6 0000 20 0000 0 0000 x p rimm MoveP 3 s0000 20 0000 o o000 4 8 0000 3 0000 0 0000 at lt l 5 30000 0 1130 40 0000 3rd son B essinZ nd face Mesh Density Control Points 1 0004 gt gt 0 000 1 035 9 000 2 E ion aml 12000 1 035 2 000 J y lmm ihh 0 000 22 070 1 000 12000 22070 1 000 Defaut view AoaocP lt lt Goo 20000 1 000 T Elements 941 Nodes 1 Fig 29 Spot welding geometry with mesh generated N T Refine mesh of Object No 3 with elements 100 Note Coating layer and Interface layer cannot be refined Fig 30 Advanced mesh generation for refining the mesh in an object with user specified number of elements Common functions At the top of Fig 21 seven common function buttons are included Reset is to set the graphics to normal scale fitting the window Zoom is to zoom in or out and to move the displayed graph Image isto save the displayed graph in bitmap picture Save As isto save the data file to another name Save is to save the data file 2011 SWANTEC Software and Engineering ApS www swantec com 48 SORPAS User Manual Version 10 6 Undo is to discard any changes after the last save of the data file Cancel _ is to close the input windows without saving modified data OK is to close the input windows and save the data fil
101. imulation Automated verification of contact resistance Automated optimisation of weld current Automated generation of weldability lobe Fully automated Weld Planning Editions SORPAS Standard FA o SORPAS Professional SORPAS Enterprise Explanations of the main functions e Graphic user interface for data input including the Input Wizard and the Data file editor for design of geometries and selection of materials from integrated databases for electrodes weld parts and coatings and settings of welding process parameters e Automatic mesh generation to automatically generate FEM mesh for spot welding according to user defined number of elements and density distributions 2011 SWANTEC Software and Engineering ApS www swantec com 6 SORPAS User Manual Version 10 6 Electrical model calculates the current distribution and heat generation depending on types of weld current and weld material combinations Thermal model including metallurgical model calculates the heat transfer temperature development materials properties changing with temperature and weld nugget formation Mechanical model calculates the mechanical reactions including deformation of materials evolution of contact areas at interfaces stress and strain status depending on welding machine characteristics and dynamics Graphic display of results display of simulation results incl
102. in Fig 1 a list of parameters obtained in the simulation appears as shown in Fig 55 Process Parameter Curves Peak Temperature in Materials Contact Resistance of Interfaces Nodal Temperature Curves Nodal Current Density Curves Nodal Voltage Curve between two nodes Nodal Resistance Curve between two nodes Nodal Displacement Curve between two nodes WGC Weld Growth Curves ability Lobe Curves WSS Weld Schedule Specifications Report of Simulation Final Temperature Distribution and Weld Results Fig 55 Menu items of Results The first three items are for displaying the process related parameter curves Peak Temperature in Materials is to display the peak temperature in each material as function of time Contact Resistance of Interfaces is to display the contact resistance at each interface as function of time The second group of five items are for displaying the nodal value curves The three items in the middle are for displaying the Weld Growth Curve and Weldability Lobes and the Weld Schedule Specifications when available Report of Simulation is for generating and showing the report of simulation with both input conditions and the selected main simulations results Final Temperature Distribution and Weld Results is for displaying the final temperature distribution together with the final weld nugget sizes and weld strengths at each weld interface or in each sheet workpiece 2011 SWANTEC Softw
103. ineering ApS www swantec com 5 gt SORPAS User Manual Version 10 6 1 Download the installation program usually in zipped format 2 Start the downloaded program Install exe All program components of SORPAS including standard databases will be installed 3 Typical case studies are presented in the Gallery at the SWANTEC website After installing SORPAS on the hard disk three shortcuts will be automatically created in the menu list of Programs in the Start menu and also on the desktop SORPAS 10 6 Enterprise for starting the simulation software Watcher 10 6 for watching the simulation progress while it is running o SORPAS 10 6 User Manual for the PDF version of this user manual Editions of SORPAS Three editions of SORPAS have been released including the Standard Edition the Professional Edition and the Enterprise Edition The automated procedures for optimization of the weld current prediction of the weldability lobes and verification of the contact resistance are available only in the Enterprise Edition which gives users the ultimate benefits to ensure developments and optimizations before welding The following table shows the different functions included in each Edition Functions Graphic User Interface for data input Automatic mesh generation Electrical model Mechanical model Graphic display of results Editor for databases Build in databases Single simulation Batch s
104. ing for prediction of the optimal weld parameters More details for the automated optimization procedures are described in Sections 3 3 6 The weld nugget size in diameter or in height can be targeted with options at the overall maximum overall minimum or at any specified sheet object EE SoRPAS 1 1 dat Se te wie e Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help j so as SORPAS R Version 10 1 Enterpris RO C 1995 2010 by SWANTEC Software and J cacsonart ApS All rights reserved Elements 1000 Mesh Simulation Optimization Procedures Process simulation Number of welds 1 Options Optimization of weld current Generation of weldability lobe Weld planning for optimal start weld schedule gt Targeting weld nugget size C Max Min C Sheet Object No Diameter C Height I Automatic GotoEdt Save lt Back Ste sorpass y Es Tim Elements 941 Nodes 1 Fig 18 The Input Wizard step 7 to select procedure for simulation and optimizations 2011 SWANTEC Software and Engineering ApS www swantec com 36 SORPAS User Manual Version 10 6 3 2 Weld Planning and WTD The Weld Planning is a brand new function developed and released with SORPAS Version 10 It can automatically predict the Weld Schedule Specifications WSS with optimal weld current weld force weld time and
105. ion x Y mm soroas Cancel g Fig 35 Window for inserting new tools ll The geometry of each tool is defined by a list of corner points defined with x and y coordinates see Fig 34 This list can be modified or extended Button is to modify the co ordinates of the selected point gt gt is to insert a new point of co ordinates below the selected point or otherwise to the end of the list and lt lt is to remove the selected point Note The geometry of tools is defined with segments of straight lines which defines how the electrodes are mounted into the welding machine The co ordinates of each corner point should be input sequentially in the counter clockwise direction Ill Click Move to change the location of one or more tools The Moving window is the same as shown in Fig 23 The selected tools can be displaced in both x and y direction they can be flipped around x or y axis or they can be rotated with any angle IV Click Size to change the width or the height of the selected tools The Sizing window is the same as shown in Fig 24 5 Select the way of mechanical loading control Any tool can be defined to move The movement can be controlled by force or by velocity however only maximum two tools are allowed to be controlled by force When two tools are controlled by force the user shall make sure the forces are to be balanced When two tools have been selected for force control no other too
106. is for transferring data between database files An edit box and a list window are designed for input the geometry of electrodes The geometry of the electrode is defined in the edit box with the x and y coordinates of the contour points and the radius of curvature r The points must be defined in the counter clockwise direction If the direction is wrong ERR will be displayed in the graph The electrode is highlighted in yellow color with red lines on the border in the graphics window The coordinates for the contour points shown in the list window can after selection be modified in the edit box The selected point is shown as a red dot in the graph 2011 SWANTEC Software and Engineering ApS www swantec com 102 SORPAS User Manual Version 10 6 Button gt gt is to insert point co ordinates below the selected point or otherwise to the end of the list lt lt is to remove the selected point and is to modify the selected point A round corner may be defined by giving the radius of the corner to the starting point connecting to the next point It is obvious that the radius should be larger than a half of the distance between the two points A positive radius defines a convex round corner while a negative radius defines a concave round corner In order to avoid confusion in the orientation an exact half circle should be defined by two pieces of arcs by inserting a middle point There are four butto
107. l properties including distribution of hardness and martensite formation etc Show results of Residual stresses residual strains and cracking risks Options and operations of graphic display SORPAS User Manual Version 10 6 Database Edit and modify databases of materials electrodes workpieces and machines Help Information about the user and SORPAS It is recommended that all new users of SORPAS shall take the training course 1 2 days on the fundamental knowledge and the practical procedures for using the software with hands on exercises before starting to work with SORPAS In this User Manual brief background knowledge and general introduction of SORPAS are given in Chapter 1 The examples for applications of SORPAS are presented in Chapter 2 The instructions on operations of SORPAS are described in Chapter 3 2011 SWANTEC Software and Engineering ApS www swantec com 10 SORPAS User Manual Version 10 6 Chapter 1 Introduction SORPAS is professional welding software for Simulation and Optimization of Resistance Projection And Spot welding processes It is developed with an integration of the FEM and the engineering welding expertise It is commercially applied in industry for supporting evaluation of the weldability of weld combinations and the design of parts and electrodes as well as optimization of the process parameter settings in resistance welding 1 1 What is FEM The finite element met
108. ld nugget with width and height of the weld nugget in each workpiece is shown together with the Final Temperature Distribution and Weld Results Animated display of variable distributions can be displayed by the Animations menu and then find which variable to show The metallurgical results can be seen in the Metallurgy menu The residual results can be seen in the Residuals menu The weld strengths are presented with the Final Temperature Distribution and Weld Results the Weld Growth Curves and the Weldability Lobe Curves The examples are presented as follows For more details about how to make simulations with SORPAS please refer to Chapter 3 2011 SWANTEC Software and Engineering ApS www swantec com 19 SORPAS User Manual 2 1 s1 s1 dat Version 10 6 The example s1 s1 is for simulation of spot welding of two 1 mm mild steel sheets using type B electrode with a conical tip face diameter of 6mm This example has also been used in Chapter 3 for describing the main functions of the software The process parameters used for the simulation are shown in Table 2 The report of simulation generated by SORPAS is shown in Fig 2 Table 2 Welding parameters for soot welding example sl s1 Filename Squeeze time Weld time Hold time Current RMS Current Force type ms ms ms kA kN s1 s 40 160 100 8 3 AC 2 2 S O RO 3 S SC2ZAS R Version 10 1 Enterprise Edition T C 19
109. ls about the databases are described in Section 3 9 It is recommended to create all new or special electrode designs in the database before preparing the simulations and optimizations ZE sorpas s1 s1 dat o amp File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help sorpa S SORPAS R Version 10 1 Enterprise Edition C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved Upper Electrode Fom Type BO d2 6 d1 16 150 5821 2009 M Up down Material I Water cooling Category Electrode materials gt Flowrate 4 000 l min Material ISO 5182 A2 2 Electrode CuCZr vy Water T 20 000 C Lower Electrode Form Type BO d2 6 d1 16 ISO 5821 2009 v M Up down Material Water cooling Category Electrade materials v Flowrate 4 000 l min Material ISO 5182 A2 2 Electrode CuCrZr _v Water T 20 000 C SORDS Cancel Save lt Back Next gt Fig 15 The Input Wizard step 4 to select the electrodes and their materials from databases 2011 SWANTEC Software and Engineering ApS www swantec com 33 SORPAS User Manual Version 10 6 Step 5 Welding machine and current settings The welding machine gun can be selected from the machine database The type of electrical power source such as AC DC and
110. ls are allowed to be controlled by 2011 SWANTEC Software and Engineering ApS www swantec com 55 SORPAS User Manual Version 10 6 6 force but they can then be controlled by velocity Stationary tools should be controlled by velocity and setting velocity to zero default for all tools If a different tool should be controlled by force then change one of the force controlled tools to velocity control and then select another tool to be controlled by force Note The force or velocity with two components in x and y is defined as a function of time Positive value in y direction means upward and in x means to the right whereas negative values mean the opposite directions Normally the tools are chosen as rectangles which ensure contact with the electrodes Tool no l in the spot welding example is chosen to be the moving tool while Tool no 2 is stationary The movement of Tool no 1 is determined by the specified welding force Similar to the real procedure on a welding machine the electrode force needs time to build up to the required level however the building up time in SORPAS can be shorter comparing to actual welding machines In the example the electrode force is 3 KN and the building up time is set to 20 ms therefore the mechanical loading for Tool no 1 is as follows t Fx Fy 0 0 0 20 0 3 0 Tool 2 is stationary therefore the mechanical loading is set to velocity control and the velocity input is set to
111. lve the problem Check the entire list of density data for every material and remove the zero values ERR1105 Solution failed due to null flow stress data This error occurs when at least one of the materials had zero flow stress Proposed way to solve the problem Check the entire lists of flow stress data for every material and remove the zero values ERR1106 Solution failed due to null machine electric capacitance data This error occurs only when applying capacitor discharge CD machine and the machine capacitance was set zero Proposed way to solve the problem Correct the machine capacitance data 4 3 Run time errors ERR2001 There was no model selected for simulation All models were unchecked or not included for simulation Proposed way to solve the problem Go to lt Edit Data File gt and then lt Process Control gt to select the necessary models for simulation ERR2002 Velocity control is applicable only for deformation Velocity of tool is only meaningful for deformation of materials It is unrealistic to run a simulation with velocity control but no deformation Proposed way fo solve the problem Either change to with deformation or to force control without deformation ERR2003 Cannot continue with deformation from a non deformation calculation It is not allowed to mix the history of simulations with and without deformation Proposed way to solve the problem Choosing the same c
112. n Strength ISO 14272 2000 Shear Strength ISO 14273 2000 and Peel Strength ISO 14270 2000 So it is possible to optimize the welding process window and parameters according to the resulted weld strengths 1 3 4 Production maintenance SORPAS can also be applied for troubleshooting welding problems in existing production lines By applying the same design of the workpieces and the electrodes with the actual process parameter settings the welding process can be simulated and evaluated on the computer The development of temperature and the formation of the weld nugget can be illustrated graphically on the computer throughout the entire welding process In this way it is possible to identify the reasons for the problems and to understand why and when the problem occurs in the process thus to find out solutions for the problems This can help the welding engineers near production lines to diagnose and solve the welding problems in a very efficient way 1 3 5 Education and training SORPAS has been designed with engineering expertise in resistance welding and equipped with graphical illustrations of the welding process It has been frequently applied for supporting education and training for new engineers to get into the welding job much more quickly 2011 SWANTEC Software and Engineering ApS www swantec com 16 SORPAS User Manual Version 10 6 Chapter 2 Examples In order to demonstrate how SORPAS can be used for actual
113. n for soot welding example to display the heat affected zone or an isotherm line defined by the user or to show the temperatures of two nodal points as shown in Fig 69 Define Isotherm Line x Isotherm line at user specified temperature C Show temperatures at two nodal points no Cancel Fig 69 Options for display of HAZ isoth or temperatures of two nodal points Button Nugget is to show the maximum Define Isotherm Line Exo No isotherm line c Isotherm line at user specified temperature 700 CC C Show temperatures at two nodal points no erm line with user defined temperature nugget with solid filling or only a contour line Button Mesh is for displaying the mesh and nodal numbers Button Scale is for users to define the scale for the colour sp 2011 SWANTEC Software and Engineering ApS www swantec com ectrum used for distribution of parameters 85 SORPAS User Manual Version 10 6 Button Image is to save the graph in bitmap file either as a single picture or as a series of pictures for making animation videos as shown in Fig 70 Select Type of Image to Save x Save single image of the present display Save series of images for making animation Cancel Fig 70 Select type of images to save as single image or series of images Button lt lt is to fast rewind the animation to the beginning Button lt is to backward
114. n in green color Automated verifications of contact resistance factor An automated procedure is implemented in SORPAS to automatically verify the value of the surface contamination multiplier dirty clean factor according to a given weld nugget size obtained from an actual welding test An iterative 2011 SWANTEC Software and Engineering ApS www swantec com 65 SORPAS User Manual Version 10 6 algorithm has been implemented for searching the relevant surface contamination multiplier As seen in Fig 36 clicking on the Verification of contact resistance to get nugget size the input box for a specified weld nugget size is activated Giving a tested weld nugget size for the specified materials the relevant contact resistance factor can be found verified by running the automated procedure as described in section 3 5 3 3 4 Preferences When making new simulation with the Inout Wizard or the data file Editor default values will be taken from the Preferences including the choices of materials electrodes welding machine and some other parameters as shown in Fig 44 It will still be possible to change the values of all data in the Input Wizard and in the data file Editor after the default values taken from the Preferences The simulation will run only according to the data finally defined and saved in the data file Preferences Save Cancel Elements per Sheet 500 IV Stop Simulation at Electrode Melting M Nugget Size at
115. ning Results Animations Metallurgy Residuals View Database Help S O RO 3 S 202245 R Version 10 1 Enterprise Edition 7 C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved Martensite fraction 1 000 0 900 0 800 0 700 0 600 0 300 0 200 0 100 Le Proc time 1 740 s Max Mar 2 0 000 Mar 236 1 000 Mar 253 1 000 Min Man pg 9 000 Mar ae oa Man 229 0 000 A2 c DP600 S 400 Tmm 0 000 Fig 80 Distribution of une racion of martensite formation 2011 SWANTEC Software and Engineering ApS www swantec com 94 SORPAS User Manual Version 10 6 3 7 6 Distribution of Hardness The distribution of hardness is dependent on the chemical composition such as the Carbon Equivalent of the steel as well as the cooling rate usually measured at 700 C Fig 81 shows an example of the hardness distribution ZE SORPAS DP TRIP_watercool dat o a File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help SORPAS R Ve Z 10 1 E Editi SORO SS Chess 200 by SWANTEC Software and Engineering ApS All rights reserved Hardness HV 5 734E 02 5 161E 02 4 587E 02 4 014E 02 e Cy w 2 867E 02 2 294E 02 1 720E 02 1 147E 02 5 734E 01 La Thh 0 000E 00 Proc time 1 740 s Max HV 2 0 000 HV 236 4596 HV 253 573 4 Min HV 2 0 000 HV 236 2257 HV 253 425 0 Fig 81 Distribution
116. normal phenomenon that was not mentioned above please note down the problem and inform the developers support swantec com together with the original data file filename dat and the associated material database Material dbs 2011 SWANTEC Software and Engineering ApS www swantec com 114 SORPAS User Manual Version 10 6 Appendix End Face in Z for Block Model Cylinder definition 5 gt Cross section on x y plane on the screen vt ooo is Ey Geometry on 3rd dimension end face in Z 1 Angle to x axis 0 radius 1 mm aD Xc Yc 2 Angle to x axis 90 radius 2 5 mm prea le Xe Vo 2011 SWANTEC Software and Engineering ApS www swantec com 115 SORPAS User Manual Version 10 6 Cylinder definition Half in Z A Cross section on x y plane on the screen Vs Pe _ 7 F Geometry on 3rd dimension end face in Z 1 Angle to x axis 0 radius 1 mm 2 Angle to x axis 90 radius 2 5 mm r 25 k Xc Yc 2011 SWANTEC Software and Engineering ApS www swantec com 116 SORPAS User Manual Version 10 6 How to make a ball with cylinder definition 2 5 Cross section on x y plane on the screen vt X O l Geometry on 3rd dimension end face in Z 1 Radius 2 5 Half in Z Bulk thickness in Z Bulk thickness in Z aa Xe Yc 4 i Xc Yc 2011 SWANTEC Software and Engineering ApS www swantec com
117. ns in the middle for building up the electrode The Delete and Insert buttons are for removing object and adding new object the Zoom and Reset buttons are for zooming and moving the objects and resetting to full view of the whole electrode similarly as described in Section 3 3 1 see Fig 31 Five general function buttons are located in the upper right corner of the electrode database editor e Image button is to save the picture of the selected electrode as a bitmap picture e Save button is to save the electrode data into database e Undo button is to discard changes after the last save of the database file e Cancel button is to close the editor of database without saving newly entered data e OK button is to close the editor and save the database 2011 SWANTEC Software and Engineering ApS www swantec com 103 SORPAS User Manual ZE sorpas untitled Electrode Database File Input Mesh Simulation Batch Run Image Save Undo Cancer OK Optimization Version 10 6 n Weld Planning Results Animations Metallurgy Residuals View Database Help Remove AddNew Duplicate Load Electrode from Database Nog af Electrode List Type BO d2 5 d1 13 IS0 5821 2009 Definition of the Current Electrode Electrode Name Type BO d2 5 d1 13 IS0 5821 2009 Delete Inset Zoom Reset E 2 Object 1 4 gt Geometry of Object 6 5000 241
118. nual Version 10 6 A list of data files must be put into the batch file before starting batch simulations In the main menu as shown In Fig 1 click File and then choose either New Batch File or Open Batch File as shown in Fig 48 the batch file will be opened New Input Wizard Open Data File Save As Save As Version 9 0 Save As Version 8 0 New Batch File Open Batch File Print Close All Clean Disk Space Exit Fig 48 Menu items of File After opening the batch file data files can be added into the batch file with the batch file editor opened by clicking the main menu item Input and then clicking the menu item Edit Batch File A dialog window for editing the batch file will appear as shown in Fig 49 Eidt Batch File Active data file 7 s1 s1 Add data file Es Without extension name lt lt Browse gt gt Add a data file Browse gt gt Add a batch sl s1 s1 s1_Coating 3 sheets s1 s1_watercool s1 s1_Gap 1force s1 s1_Gap 2force Cross Wire Cancel Fig 49 Editor for the batch file Button Browse gt gt Add a data file is to add a data file to the file list by browsing the data files in the computer Button Browse gt gt Add a batch is to add a batch of data files from another batch file to the new batch file by browsing the batch 2011 SWANTEC Software and Engineering ApS www swantec com 69 SORPAS User Manual Versi
119. of hardness 3 8 Display the Results of Residuals Because the calculations of the Residuals are based on the metallurgy results the simulation shall complete with sufficient cooling time to make sure the sheets have cooled down to below all phase transformation temperatures The functions for Residuals are available by clicking the main menu item Residuals in Fig 1 If the results of residuals were not generated automatically it is possible to get again by clicking on Run Calculation of Residuals Then the results of Residual stresses Residual strains and Cracking risks can be displayed by clicking on the menu list as shown in Fig 82 2011 SWANTEC Software and Engineering ApS www swantec com 95 SORPAS User Manual Version 10 6 Run Calculation of Residuals Residual Stresses Residual Strains Cracking Risks Fig 82 Menu items of Residuals 3 8 1 Distribution of Residual Stresses Fig 83 shows an example of the distribution the residual stresses in radial direction The residual stresses have been calculated based on elastic unloading cooling shrinkage and phase transformations El ZE SORPAS DP TRIP_watercool dat gt File Input Mesh Simulation BatchRun Optimization TEE Results Animations Metallurgy Residuals View Database Help so RO BS SORPAS R Version 10 1 Enterprise E C 1995 2010 by SWANTEC Software and Comes inearing ApS AN rights reserved Res stress X MPa 5 649E 0
120. of the workpiece database editor e Image button is to save the picture of the selected workpiece as a bitmap picture e Save button is to save the workpiece data into database e Undo button is to discard changes after the last save of the database file e Cancel button is to close the editor of database without saving newly entered data e OK button is to close the editor and save the database 2011 SWANTEC Software and Engineering ApS www swantec com 106 SORPAS User Manual Version 10 6 BE SORPAS Untitled o o ea File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help SORPAS R Version 10 1 Enterprise Edition Workpiece Database Image Save Undo Cancel OK so RO as C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved Remove AddNew Duplicate Load Workpiece from Database No3 af Workpiece List Embossed ad Workpiece Name Embossed Definition of the Current Workpiece Delete Inset Zoom Reset 1 Object 1 4 gt Geometyy of Workpiece 27500 1 2000 0 0000 omo 2o ooo x y rimm MoveP osoo ooooo 3 0000 2 7500 1 2000 0 0000 SJ 100000 1 2000 0 0000 10 0000 3 2000 0 0000 1 9430 3 2000 0 0000 1 2500 20000 0 0000 O Fig 90 Editor for workpiece database 3 9 4 Machine database The machine database has b
121. on 10 6 files in the computer Button gt gt is to insert a data file manually from the edit box into the file list below a selected filename or otherwise to the end of the list Button lt lt is to remove the selected data file from the list The data file has to be created before adding into the data file list The selected data file will be the active data file after closing the batch file editor The batch file will be automatically saved when closing the editor by pressing OK All data files belonging to the same batch file have to be located in the same folder together with the batch file itself Running batch of batch simulations can be done by creating a new batch file with a new name such as All Batches fil and then add the existing batch files with lists of data files into the new batch file The new batch file having now batch of batch files or all data files from the other batch files can run with the functions for Batch Run When the simulations of all data files in the new batch file are finished each batch file can be opened individually to view the results Running multiple optimization procedures can be done similarly as running batch of batch simulations A batch file will be automatically created for each optimization procedure weld growth curve and weldability lobes after it is started This may take up to several minutes as all data files will be created and mesh generated before simulations When
122. on names nodal current density with cud nodal voltage with vol nodal resistance with res and nodal displacement with dis e ZE SORPAS s1 s1 dat CIE File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help S O RO 3 S S2RPAS R Version 10 1 Enterprise Edition 7 C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved 540 352 J 486 317 4 gt Scale 432 282 7 378 247 7 324 211 7 270 176 J 216 141 7 162 106 7 Nodal resistance Ohm 108 070 gt i Oy 54 035 7 N201 0 000 T T I T l N4241 0 0 60 0 120 0 180 0 240 0 300 0 Process time ms Fig 63 Nodal resistance curve 3 6 3 WGC Weld Growth Curve When the optimization of weld current is completed for generation of the weld growth curve a batch file has been made of data files with increasing weld current The batch file has the same name as the initial data file but with an extension name fil It can be opened by clicking on the main menu item File and then Open Batch File When the batch file is opened the weld growth curve will be displayed automatically or by clicking on the main menu item Results and then clicking on the menu item WGC Weld Growth Curves The control tools as shown in Fig 64 will be available including 1 the list of types of the weld grow
123. ondition of deformation as the previous part of the simulation ERR2004 Cannot continue without deformation from a deformation calculation It is not allowed to mix the history of simulations with and without deformation 2011 SWANTEC Software and Engineering ApS www swantec com 113 SORPAS User Manual Version 10 6 Proposed way to solve the problem Choosing the same condition of deformation as the previous part of the simulation ERR2101 Solution failed due to negative Jacobian This error occurs due to large distortion of one or more elements during deformation Proposed way fo solve the problem It is difficult to overcome this problem without regenerating the mesh One of the ways to improve the situation is to make a finer initial mesh around the place where the largest mesh distortion occurred Reducing the time step increment may also help a little ERR2102 Solution failed due to deformation does not converge This error occurs when the calculation of deformation is not converged Proposed way fo solve the problem Reduce the time step increment and re do the simulation ERR2104 Solution failed due to temperature becomes unrealistic This error occurs when the simulated temperature is unrealistically too high Proposed way fo solve the problem Check the process settings and materials data correct the errors and re do the simulation 4 4 Remarks If users encountered any error or ab
124. opped and the active data file had been changed it should return to the same data file where it was stopped before continuing Continue from Latest Simulated Data File is to automatically find and continue simulations from the latest simulated data file 3 5 4 Run Weld Planning Clicking the main menu item Weld Planning in Fig 1 the menu items for weld planning will be displayed as shown in Fig 53 WTD Weld Task Description Continue Weld Planning Neld Schedule Specifications 1 Growth Curves WLC Weldability Lobe Curves Fig 53 Menu items of Weld Planning The Weld Planning always starts with the Weld Task Description WTD with information of the sheets electrodes and type of welding machine as explained in Section 3 2 After all information and user preferred parameters have been prepared clicking on the Start button on the WID window see fig 19 the Weld Planning will be started to run fully automated When it is completed the WSS Weld Schedule Specifications will be obtained with the optimal welding process parameters as described in Section 3 6 5 2011 SWANTEC Software and Engineering ApS www swantec com 72 SORPAS User Manual Version 10 6 3 5 5 Simulation watcher After invoking the simulation the window of SORPAS will be automatically closed and calculations will then run behind the screen At the same time a status window for watching the progress of simulations will
125. out One for weld current optimization by automatically generating the weld growth curve at given weld force and time The weld current range can be predicted with indication of splashes The other is for prediction of the complete weldability lobes Two types of weldability lobes can be generated 1 with varying weld current and time but constant weld force and 2 with varying weld current and force but constant weld time The weldability lobes can be predicted with reference to the user specified reference nugget sizes minimum nugget diameter maximum nugget diameter and minimum nugget height penetration in the thinnest outer sheet The splash limits are predicted automatically The third option is to use the weld planning features where SORPAS automatically finds the most optimal welding parameters force time pulses and current based on an iterative simulation process 1 3 3 Prediction of the weld quality and properties after welding With the newly added functions for simulations of the metallurgical properties and residuals it is possible to predict the distribution of austenization and martensite formation distribution of hardness as well as residual stresses and cracking risks in 2011 SWANTEC Software and Engineering ApS www swantec com 15 gt SORPAS User Manual Version 10 6 the welds after welding The weld strengths are also calculated referring to the test methods described by the ISO standards including Cross Tensio
126. program to ease the definition of geometries in new simulation files The workpiece database is open for users to input workpiece designs Click Database menu in Fig 1 and select Workpiece Database The editor for the workpiece database is shown in Fig 90 The Workpiece List is a dropdown list for all the workpiece design in the database Users may select any one to display the workpiece design data The name of the current workpiece can be entered with the edit box below the workpiece list Selection of the workpiece can also be done with the Scroll Bar The number on the left side of the scroll bar is the ID number of the current workpiece displayed The number on the right side is the total number of workpieces in the database It is possible to add new duplicate existing and remove workpieces The buttons for editing the workpiece list are described below e Duplicate button is to add a new workpiece at the end of the workpiece list with the same design as the selected workpiece e Add New button is to add a new workpiece at the end of the workpiece list with no data listed e Remove button is to delete the selected workpiece from the database Load Workpiece from Database is for loading workpiece design from another workpiece database into the current one It is for transferring data between database files An edit box and a list window are designed for the coordinates of the workpieces The geometry of the workpiece is defined in the e
127. r limit 2 5 KN to a higher limit 5 kN and an increment 0 5 kN and for each weld force with increasing weld current from a lower limit 4 kA to a higher limit 14 kA with an increment 1 kA The limits can be from the welding machine limits or with a wider range so that the software will find the actual welding process window The series of data files are automatically generated in a sub folder and included in the batch file s1 s1_lobe force fil It can be opened by Open Batch File After opening this batch file the weldability lobe is displayed first with the weld nugget diameters see Fig 11a The red points indicate oversized weld nugget or splashes at the interfaces between sheets The orange color indicates a profound likely hood of splash occurring The purple points indicate electrode melting The gray points with open markers indicate no weld and with solid markers indicate undersized welds The green points indicate welds with a nugget in between the maximum and minimum weld nugget diameters as seen in Fig 11a The weldability lobe can be shown further with Cross Tension Strength Shear Strength and Peel Strength see Fig 11b where the open markers indicate Interface Failure and solid markers indicate Plug Failure More details on how to prepare data for making the weldability lobes are described in Section 3 3 6 SOR POS ea aie crated Mamata o tt a arat Weld force kN Weld current kA Weld current kA
128. r modify the high density points to the area with most changes or add more density control points to get better mesh distribution For more details please read Section 3 3 1 1 1 2 Time step In order to calculate the highly non linear and dynamic changes of variables through the welding process the process time is divided into small steps during simulations The FEM calculations will be carried out incrementally through the entire welding process to simulate the dynamic changes or the gradients of variables in time such as the temperature development in resistance welding process The time step has essential influence on the accuracy of FEM simulations regarding to the dynamics of variables changing in time The smaller the time step is divided the more accurate results can be obtained regarding to the dynamic changes of variables But it will also increase the number of calculations thus the computation time In SORPAS it is possible to use individual time steps for simulations in different stages of the resistance welding process namely the squeeze weld hold off and idle stages Users can also decide how often to save the simulation results for showing animated display of the results by skipping some steps especially when using smaller time steps For more details please read Section 3 3 4 2011 SWANTEC Software and Engineering ApS www swantec com 12 SORPAS User Manual Version 10 6 1 2 How to make simulations with SOR
129. r optimization of weld current see Fig 40 It is requested first to specify which pulses will be optimized If there are more than one pulse the average value of the RMS values of current of alll selected pulses will be used for optimizations and the relative ratio of the initially specified RMS values of current between pulses will be preserved during the optimization Two optimization procedures can then be defined as following The first procedure is to automatically generate the Weld Growth Curve WGC The weld growth curve shows the weld nugget sizes growing with increasing weld current A series of simulations will be prepared and run automatically according to the given range of the weld current from a lower current limit to a higher current limit with an increment that defines how many points to be simulated as shown in Fig 40 After all simulations are finished the weld growth curve will be obtained as for example shown in Fig 9 as described in Section 2 8 On the simulated weld growth curve the splash points are predicted and indicated with red color the points with no weld are shown in black color whereby the weld current range can be obtained with points shown in green color Sometimes when the green points are close to the red splash points within 5 difference they will appear as orange color The weld nugget size obtained at each weld current can also be shown on the curve 2011 SWANTEC Software and Engineering ApS w
130. r weld growth curves b list of 4 kinds of weld quality measures c and d list of positions where the weld quality values are measured An example of the weld growth curve is shown in Fig 9 in Section 2 8 with detailed description of the colors and indications on curves Please note that the simulation will be automatically stopped if any electrode is melted thus it may be seen that the nugget size may be getting smaller and the welding time is not completed for some splash points due to this hard stopping 3 6 4 WBL Weldability Lobes The weldability lobe shows the welding range of two process parameters with reference to the specified weld nugget sizes Two types of the weldability lobe as defined in ISO 14327 2004 can be predicted automatically 2011 SWANTEC Software and Engineering ApS www swantec com 80 SORPAS User Manual Version 10 6 The first type is with varying weld current and time but constant force The control parameters can be defined as described in Section 3 3 6 and the simulations can be started as described in Section 3 5 3 When the simulations for generation of the weldability lobe are completed several batch files have been made containing the data files with varying weld time and current The main batch file has the same name as the initial data file but with an extension name fil which contains all the data files for the complete weldability lobe Several other batch files were also created fo
131. r weld growth curves at each weld time The weldability lobe can be opened by clicking on the main menu item File and then Open Batch File When the batch file is opened the weldability lobe will be displayed automatically or by clicking on the main menu item Results and then clicking on the menu item WBL Weldability Lobe Curves Fig 10 shows an example of the first type of weldability lobe as described in Section 2 9 In order to get the welding range three weld nugget sizes can be given as references minimum nugget diameter maximum nugget diameter and minimum nugget height penetration in the thinnest outer sheet The black line shows the lower border of the welding process window satisfying both the minimum nugget diameter and the minimum nugget height penetration The red line shows the upper border of the welding process window defined with the maximum nugget sizes and or splash expulsion Accordingly the splash expulsion points and over sized weld nuggets are shown in red color the under sized weld nuggets are shown in black color whereas the points within the welding process window are shown in green color It is also possible to read the weld nugget size at each point by moving the scroll bar on the control tool The second type is with varying weld current and force but constant time The control parameters can be defined simulations started and results viewed similarly as the first type of weldability lobe Fig 11 shows an
132. rrecting the errors ERROOOS3 Cannot write to file This error usually occurs when trying to write to a file which is read only or being opened by another program Proposed way to solve the problem Check the file attributes and close the file if it is opened 4 2 Errors related to input data and mesh generation ERR1001 Null thickness detected in block model The thickness of objects in block model is the 3 dimension perpendicular to the screen It must not be zero Proposed way to solve the problem Input the correct thickness ERR1002 Too few density control points Check if any object with zero area This error occurs when any object was un defined or had zero area Proposed way to solve the problem Check the co ordinates of the object and correct the errors 2011 SWANTEC Software and Engineering ApS www swantec com 111 SORPAS User Manual Version 10 6 ERR1003 Coordinates error detected in object no xx This error occurs when the corner point co ordinates of the object were defined in a wrong sequential order the correct order is counter clockwise or the area of the object was zero Proposed way to solve the problem Check the co ordinates of the object and correct the errors ERR1004 Coordinates error detected in tool no xx This error occurs when the corner point co ordinates of the tool were defined in a wrong sequential order the correct order is counter
133. rrent with a RMS value of 8 kA and a weld time of 10 cycles is used without up slope and down slope Water cooling A new function for water cooling has been developed to simulate water cooling in electrodes as function of water temperature and flow rate liter minute The water cooling is added by inserting a special Tool block fitting exactly the water cooling cavity in the electrodes The water cooling can be added in the electrode database so it will be automatically loaded into the system when preparing simulations with the Input Wizard Tools no 1 and no 2 are reserved for electrical connections so the Tools used for water cooling can only start from no 3 When the check box Water cooling is checked the Tool block for water cooling will change its color to light blue indicating it is now set as water cooling Gap tools are introduced for defining gap between sheets which can be inserted in the gap at the edges of the sheets When X fix is checked the gap tool and the contacting nodal points of objects are fixed in X direction When Y fix is checked the gap tool and the contacting nodal points of objects are fixed in Y direction Otherwise the gap tool is allowed to float freely in space 3 3 4 Define simulation control parameters The last part of input data needed before starting simulation is to define the simulation control parameters 1 In Fig 21 choose the tab Simulation Control The dialog window for input of simul
134. s in geometry or in the materials 2011 SWANTEC Software and Engineering ApS www swantec com SORPAS User Manual Version 10 6 As the basic concept of FEM the problem domain geometry and materials is divided into a number of elements or mesh The procedure to divide the domain into elements is called mesh generation In SORPAS the four sided or quadrilateral shape elements are used The FEM calculations are mainly based on the values of variables on nodal points and the interpolation between the nodal points inside the elements The more nodal points or elements are divided the more accurate results can be obtained for the geometrical distribution of variables Increasing the total number of elements will increase the elements in local areas but also increase the number of calculations or the time of computation It will be efficient to get only more elements in the areas with large changes or gradients of variables but fewer elements in the areas with small changes while still keeping the total elements in a reasonable number This is the reason that the mesh density control is introduced to allow users to define where to get more elements or high mesh density at a specified total number of elements In SORPAS seven density control points are generated automatically as default They are located around the weld combination with two high mesh density points in the center area between the electrodes Users may relocate o
135. s indicate the welds within the welding process window In Fig 9b the open markers show interface failure and solid markers show plug failure together with the resulting weld strengths by cross tension tests Similarly it is also possible to show the weld growth curves with the Weld Shear Strength and the Weld Peel Strength More details on how to prepare data for making the weld growth curve are described in Section 3 3 6 Weld a b Fig 9 Weld growth curve for spot welding of two 1 mm mild steel sheets with weld time of 10 cycles and weld force of 3 KN 2011 SWANTEC Software and Engineering ApS www swantec com 27 SORPAS User Manual Version 10 6 2 9 s1 s1_lobe time fil weldability lobe current time The weldability lobe can be simulated with a series of data files automatically created by varying two process parameters namely the weld current and weld time It is organized with increasing weld time from a lower limit e g 4 cycles to a higher limit 16 cycles with an increment 2 cycles and for each weld time increasing weld current from a lower limit 4 kA to a higher limit 16 kA with an increment 1 kA The limits can be from the welding machine limits or with a wider range so that the software will find the actual welding process window The series of data files are automatically generated in a sub folder and included in the batch file s1 s1_lobe time fil It can be opened by Open
136. s of axis for displaying parameter curves All result data of the process parameter curves are saved in a text file with the same filename as the data file but extension name tot as seen in Fig 60 _ Sa File Edit Format View Help SORPAS R Simulation Result Data Dynamic Process Parameters a ProcessTime voltage current Power Resistance Meltedvol oe ze Forcel Force2 Di i ms v a w uohm mm3 mm N N Cmm 0 500000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 0 0 100000E 01 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 2250E 03 0 0000E 0 0 150000E 01 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 3375E 03 0 0000E 0 0 200000E 01 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 4500E 03 0 0000E 0 0 250000E 01 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 5625E 03 0 0000E 0 0 300000E 01 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 6750E 03 0 0000E 0 0 350000E 01 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 7875E 03 0 0000E 0 0 400000E 01 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 9000E 03 0 0000E 0 0 450000E 01 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 0000E 00 0 1013E 04 0 0000E 0
137. sds colsaens seeteetasieavites dirare call eed cele hands axeebdeceuiardeseae h hie Eak Kakek 66 3 5 RUNNING SIMULATIONS 0 ccccccscsccscsescesesecscsssscecscssesesessesessesececsessesesessesssessesassesesecsesseaesecsesasseeececsenseeeaes 67 3 5 1 Run process simulation for single weld or multiple welds cc cceceeeeeeeees 67 3 5 2 Run batch simulations 0 0 0 cece ceccc sees cesceeecoseesseescesecesecsseescaecaeccssessessseaecesessesesesseesees 68 3 5 3 RUN optimization PLOCCAUTES 02 0 2 cece ccc sesesecessees cesses cesses ceesesesececseseesseecsesseecseanseeees 70 3 5 4 RUN Weld PINNING jesisescscderndeesss eas evias catia santana hentai aiid 3 5 5 Simulation Watcher 050 06cc ecccsuesscecciscscsdiscvassecedes shane butesissSevbunestcasbucn bees sandu a a a esse 3 6 DISPLAY RESULTS AND ANIMATIONS 0ccccccccscescescssesecssesescsecsssesacsscsessscsesaesasacsscsecascacsscsecsacsecstesecateaeees 3 6 1 Process parameter curves 3 6 2 NOCadl VOIVE CUIVES 20 0 cc ccccccccccccssesscscsssssesscssussssusssssesvsecsesassecsssessassscsasescssesecsseasesesaseacaaees 3 6 3 WGC Weld Growth Curve o u cccccccccccccccccscsesssesessesecessccssuassecssssecssesecseaecsesecsecaseseaseacsaees 79 3 6 4 WBL Weldability Lobes 0 cccccccccccccccccesesssssescssesecsssecssuassecssesecssesecaseecssesecsseaseseasescsaees 80 3 6 5 WSS Weld Schedule Specifications 0 cece cece cc cee cscs cesetececseseseeecsessesee
138. ss and the Residual module for prediction of residual stresses and cracking risks in the welds have been developed and released with SORPAS These include the following functions Output of simulation results useful for metallurgical analysis including distribution of the peak temperature distribution of the cooling rate at 700 C and distribution of the cooling time from 800 C to 500 C Prediction of austenization resulted from the heating process depending on the austenization temperatures of the steels Prediction of martensite formation resulted from the cooling process depending on the martensite start and finish temperatures and the critical cooling rates Prediction of the hardness distribution depending on the carbon equivalent of the steel and the cooling rate Residual stress distribution including residual stresses in radial axial and ring directions resulted from elastic unloading and thermal shrinkage Cracking risk factor indicating the cracking risks due to residual stresses after welding 2011 SWANTEC Software and Engineering ApS www swantec com z SORPAS User Manual Version 10 6 Starting SORPAS To start SORPAS double click the SORPAS icon on the desktop or click the Start menu point to Programs and then click SORPAS 10 6 Enterprise After SORPAS started a new window will be displayed with the main menu system as shown in Fig 1 The functions of the main menu items are e
139. t Vx Vy 0 0 0 Define electric power supply The type of machine has been determined by the selected machine from the machine database which includes alternating current AC machine direct current DC machine and Inverter machine assumed as DC capacitor discharge CD machine The power input can be defined either By voltage By current or By power The Frequency is defined in the Preferences The Conduction angle is defined in the machine database only for AC machines representing the phase shifting effects of the power control and means the percentage or degree of the working part of the truncated sine curve of the current or voltage or power 2011 SWANTEC Software and Engineering ApS www swantec com 56 SORPAS User Manual Version 10 6 7 8 In the example the conduction angle is 75 which gives a curve of current starting at zero with the first 25 and then 75 with truncated sine curve for each half cycle The pulsed current voltage or power curves can be set by specifying the number of pulses and the number of heating cycles and cooling cycles of each pulse Please refer to example 3 sheets_hss1 s2 s2 to see how the pulsed current is defined The up slope weld time down slope and the RMS current value can be specified for each pulse individually If the cooling time between the pulses is set to 0 0 a stepped current can be obtained In the example sI s1 a single pulse AC cu
140. t m 229mm 37 MeiltT 2 1070 0 T 25 1560 0 Nugget max 237 mm 5_ SO 5182 A22Elec ASI 1005 W Nr 1 028 Fig 66 Final temperature distribution with weld nugget sizes and weld strengths It is optional to show the Weld nugget sizes at weld interface or in sheet The option is set in the Preferences see Fig 44 When Nugget Size at Interface is checked the weld nugget sizes will be calculated at each interface Otherwise they are calculated in each sheet There are three choices for calculating the weld nugget size at the weld interface according to the nugget sizes of the two contacting sheets i smaller ii average or iii larger up to the user preference When showing the final weld results the sheets are re ordered from top to bottom and listed in alphabetic A B C The position of the weld interface is indicated by connection bars For example A BC indicates interface between A and B while the weld strengths are obtained by pulling A from the fastened B and C 2011 SWANTEC Software and Engineering ApS www swantec com 83 SORPAS User Manual Version 10 6 3 6 8 Animations Animation of the parameter distribution is activated from the menu list as shown in Fig 56 for the following variables Temperature distribution Temperature rate distribution Current distribution Voltage distribution Deformation showing changes of geometry during welding process Strain distribution
141. tcher Stop Simulation a b Fig 54 Status window of the watcher for simulation progress a single weld simulation b multiple welds simulation and batch simulations The information displaying dynamically during the simulation includes name of data file process time weld current weld force peak temperature in all materials nugget volume nugget size and electrode displacement Two simulation progress bars are displayed showing how far the simulation is running The upper bar shows the progress of the actual simulation running while the lower bar shows the overall progress for a batch run or multiple welds Below each progress bar are the elapsed computation time and estimated remaining time for the simulation To the right the estimated total computation time for the simulation is indicated Button Close Watcher is to close the simulation watcher which has no influence to the running simulation Button Stop Simulation is to stop the running simulation 2011 SWANTEC Software and Engineering ApS www swantec com 73 SORPAS User Manual Version 10 6 The simulation progress percentage including the current number of simulation or number of weld for batch simulation or multiple welds is also displayed with the Watcher on the Windows taskbar at the bottom of the desktop 3 6 Display Results and Animations After calculation finished users can see the simulation results Click the main menu item Results
142. th curves referring to weld nugget sizes and weld strengths 2 the 2011 SWANTEC Software and Engineering ApS www swantec com 79 SORPAS User Manual Version 10 6 reference values for defining the Weld Quality Range 3 the manual correction factor for splash expulsion limit 4 the list of positions of the weld nugget sizes or strengths 5 the scroll bar to switch between each point on the curve and 6 the Scale The weld nugget sizes can be viewed by moving the scroll bar The scale limits of the axis can be changed by clicking on the Scale button and then with the dialog window as shown in Fig 59 Weld Growth Curves Ea Weld Growth Curves Weld Nugget Diameter fmm Weld Nugget Diameter mm Weld Quality Range Update weld Cross Tension Strength __ kN Weld Tensile Shear Strength kN a50 feso 55 0 gt Weld Peel Strenath kN Min Max thin Splash limit Min Max thin Splash limit Interface A B ll Interface A B a gt Scale gt Scale a i b Weld Growth Curves Ea Weld Growth Curves Weld Nugget Diameter mm Weld Nugget Diameter Imm Weld Quality Range Update Weld Quality Range Update pa pa p s pa feo fos os Min Max thin Splash limit Min Max thin Splash limit Interface A BC whfAB C v Interface A BC 4B C Interface A BC o Interface AB C Scale c d Fig 64 a Control box with functions fo
143. the Elapsed time on the simulation Watcher starts to run stop the simulation as the batch file for the optimization has been created For weldability lobe only the one fil file without any number attached to the end has the complete list of all data files Adding the batch files of different optimizations to a new batch file with a new name such as All Batches fil similar to running batch of batch simulations multiple optimizations can be carried out by running this new batch file with the batch run functions When the simulations of all data files in the new batch file are finished the optimization results weld growth curve or weldability lobes can be displayed by opening each corresponding batch file individually 3 5 3 Run optimization procedures With the Input Wizard the optimization procedures can be started by simply clicking on the Start button at step 7 after defining the optimization control parameters as explained in Section 3 3 6 The main menu item Optimization in Fig 1 is used for starting the optimization procedures It includes the menu items as shown in Fig 50 2011 SWANTEC Software and Engineering ApS www swantec com 70 SORPAS User Manual Version 10 6 Optimization of Weld Current Optimization of Weld Current Generation of Weld Growth Curve Generation of Weld Growth Curve Generation of Weldability Lobe Generation of Weldability Lobe Verification of Contact Resistance Verification of Cont
144. the report of simulation generated by SORPAS is shown in Fig 3 Table 3 Weld parameters for example s1 s1_Coating Filename Squeeze time Weld time Hold time Current RMS Current Force type ms ms ms kA kN s1 s1_Coating 40 240 80 8 4 AC 2 2 sornonas SORPAS R Version 10 1 Eni C 1995 2010 by SWANTEC Software and Engineering ApS All rights reserved Simulated with SORPAS R Version 10 1 terprise Edition Report of Simulation 01 03 2010 12 00 00 Filename Problem ID Note C SORPAS 10 1 Demo Workis1 s1_Coating dat Spot welding 1 1mm steel Computation time Number of Elements Materials Electrodes Design of Weld Combination 11 016 000mm Type BO d2 6 d1 16 ISO 5821 2009 1 16 000mm Types Seo hes Workpieces 1 000mm 4 1 000 mm AISI 1005 W Nr 1 0288 Hr Zine Galvanize 002 AC Arbitrary rocker arm spot welding machine ey Process Parameter Settings Current kA 4 I_ems 8 4 kA 50Hz lt 2 gt lt 12 gt Process time ms Force kN Simulation Result Process Parameter Curve Weld nugget size mm g Simulation Result Temperature Distribution and Weld Nugget CC Molten 1 5608 03 1 406 03 1 2526 03 1 088 03 9 4408 02 7 9008 02 6 260 02 4 8206 02 3 280E 02 1 740 02 2 000 01
145. tion of materials and the stress and strain status Options to include special modules for Elastic Loading Thermal Stresses and Unloading Residuals The elastic loading as shown with the blue line in Fig 37 has been implemented as an option to combine with the plastic deformation that has been modeled with the flow stress stress strain Curve As illustrated in Fig 37 the elastic loading presents only at very low strain thus gives minimal effect on large scale welding It may be more important for examples with less overall deformation especially in micro welding applications The module Unloading Residuals is implemented for calculating resulted residual stresses which works only in the Off Time after the electrodes have been separated from the sheets objects 2011 SWANTEC Software and Engineering ApS www swantec com 59 SORPAS User Manual Version 10 6 Fig 37 Illustration of the elastic loading and non linear stress strain curve Thermal stresses have been implemented with calculations on the thermal expansions during heating and thermal contractions during cooling 6 Input temperature and heat transfer rate of the surrounding media normally air for calculation of the heat loss to surroundings Due to the fact that resistance welding is a very fast process heat transfer to the surroundings is not significant Only the convective heat transfer to air is considered in the simulations thereby the room temp
146. to the screen and the other wire is parallel to the screen This example shows how to define 3D geometries using the Block model with the 2 5D treatment The process parameters used for the simulation are shown in Table 8 and the report of simulation generated by SORPAS is shown in Fig 8 Table 8 Weld parameters for example Cross Wire Filename Squeeze time Weld time Hold time Current RMS Current Force type ms ms ms kA kN Cross Wire 20 40 40 1 50 DC 0 6 ee ROOS ee per a a aaa Simulated with SORPAS R Version 10 1 Simulation finished Report of Simulation 01 03 2010 12 00 C SORPAS 10 1 Demo Work Cross Wire dat Cross Wire pc Computation time Number of Elements Materials Electrodes 7 6 500 mm Type F1 4205 dt 16 R1 50 1S DSO 5182 A 1 Type F1 SO 518 AISI 1005W Nr 1 0288 Hr TAISI 1005 W Nr 1 0288 Hr Design of Weld Combination 7 eS z 2 Machine 004 DC Arbitrary spotiprojection welding machine max 60 0 kA P max 170 0 kVA F max 20 0 kN Process Parameter Settings Current kA lt 2 T T o0 20 0 40 0 60 0 20 0 I_ems 1 5 kA 50Hz Process time ms Force KN Simulation Result Process Parameter Curve 1 443 1 298 A Simulation Result Temperature Distribution and Weld Nugget CC Molten 1 580 03 1 4006 03
147. to the surface contaminants resistivity from the materials database If the two contacting materials are the same the surface contaminants resistivity of the material is used for calculating the contact resistance If the two contacting materials are not the same the lower surface contaminants resistivity of the two materials is used to calculate the contact resistance In the example ISO 5182 A2 2 Electrode CuCrZr is chosen for the electrodes Object 1 and 7 and the steel material AISI 1005 is chosen for the sheets Object 3 and 5 For the interface layers a scaling factor of 1 0 is used for all interfaces Click Move to change the location of one or more objects The Moving window is shown in Fig 23 The selected objects can be moved by displacement in both X and Y direction or to a specified point referring to the lower left corner of the objects or fit the selected objects to on top or to under bottom of other objects They can also be flipped around the X or the Y axis and rotated with any angle Moving Move FlipinX FlipinY Rotate C by displacement d 0 0000 dy 0 0000 Imm C to point at xf ie mm toon top of all other un selected objects to under bottom of all other un selected objects Select Object s Electrode Interface Workpiece Interface Workpiece Interface Electrode Tool force Tool static Water Water so RO as Cancel
148. ts In order to obtain the correct metallurgy results the simulation shall finish with sufficient cooling time to make sure all phase transformations have completed for example all sheets have cooled down to below the martensite finish temperature The metallurgy results can be seen by clicking the main menu item Metallurgy in Fig 1 and then clicking on the desired metallurgy result as shown in Fig 75 Peak Temperature Distribution Cooling Rate at 700 C Cooling Time t8 5 from 800 C to 500 C Austenization Distribution Martensite Distribution Hardness Distribution Fig 75 Menu items of Metallurgy Examples of the metallurgy results are described in the following sections 2011 SWANTEC Software and Engineering ApS www swantec com 89 SORPAS User Manual Version 10 6 3 7 1 Distribution of Peak Temperature The peak temperatures at all nodal points through the entire welding process have been recorded Fig 76 shows an example of the peak temperature distribution EE SORPAS DP TRIP_watercool dat to es File Input Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help S ORO A S Giese 2010 by SWANTEC Software and Engineering ApS All rights reserved Peak temp C 2 300E 03 2 072E 03 1 844E 03 1 616E 03 1 388E 03 1 160E 03 9 321E 02 7 041E 02 4 761E 02 2 480E 02 Le Thm 2 000E 01 Proc time 1 740 s Max Tp 2
149. uding curves of process parameters and animations of the evolution of variable distribution temperature current etc and development of the weld nugget shape and size in each material Editor for databases the user interface for editing adding removing and modifying data in the four integrated databases for material properties electrode forms designs of workpieces and properties of welding machines Build in databases four databases are integrated in the software system including the material database with properties of most commonly used materials the electrode database with most standard electrode forms ISO 5821 the workpiece database for retrievable design of weld parts and the machine database for properties of welding machines Single simulation simulation of one specific welding process with specified electrode and material combinations and given process parameter settings weld current force and time etc Batch simulation to run a batch of simulations following a list of predefined data files of different welding conditions or procedures for process optimization Automated verification of contact resistance automatically verify the contact resistance factors against a tested weld nugget size for verifying data of new materials Automated optimization of weld current two optimization functions are implemented for optimization of the weld current One is for automatically running a series of simulations according to us
150. ulation until a point of user defined process time and then continue simulation with the new data file this function is not yet implemented 3 5 2 Run batch simulations A special feature of SORPAS is to run a series of simulations automatically by using a batch file containing a list of existing data files The main menu item Batch Run in Fig 1 is used for running batch simulations which include the menu items as shown in Fig 47 Batch Run All Batch Run from Current Data File Continue from Current Data File Continue from Latest Simulated Data File Backward Forward Fig 47 Menu items of Batch Run Batch Run All is to run new simulations through the list of all data files in the batch file Batch Run from Current Data File is to run new simulations from the currently opened data file through the rest of all data files in the batch file Continue from Current Data File is to run batch simulations continuing from the interrupted simulation of the currently opened data file and then new simulations through the rest of all data files in the batch file Continue from the Latest Simulated Data File is to automatically find and continue simulations from the latest simulated data file Backward is for scrolling the active data file backward through the data file list whereas Forward is for scrolling forward through the data file list 2011 SWANTEC Software and Engineering ApS www swantec com 68 SORPAS User Ma
151. when display the weldability lobes Prediction of the Weldability Lobe with varying weld current and force The second type is the weldability lobe with varying weld current and force but constant time This can be defined in the data input window as shown in Fig 43 The maximum and minimum weld current with an increment and similarly the limits of the weld force can be defined for generating the weldability lobes Define Parameters for Weldability Lobe Active pulses to be optimized from No 1 to f1 Range and increment of weld current RMS Min 4 000 Max fi 6 000 Increment 2 000 kA MV Skip simulations after 2 splash expulsion welds Select type of the weldiability lobe varying weld time of each pulse varying weld force Min 2 000 Max 6 000 Increment 1 000 kN Range of weld nugget diameter Min 3 500 Max 6 500 Nominal 6 000 mm Note The weldability lobe is generated according to the standard procedures recommended by 1S014327 2004 so RO as Cancel Fig 43 Control parameters for generation of the weldability lobe with varying weld current and force but constant weld time After all simulations are finished the weldability lobe will be obtained as shown in Fig 11 in Section 2 10 In the predicted weldability lobe the splash points and over sized weld nuggets are shown in red color the under sized weld nuggets are shown in black color whereas the points in between are show
152. ww swantec com 62 SORPAS User Manual Version 10 6 Optimization of Weld Current Active pulses to be optimized from No 1 to f1 Select the Procedure for Optimization of Weld Current Generation of weld growth curve with increasing weld current RMS Min 4 000 Max 16 000 Increment 2 000 kA MV Skip simulations after 2 splash expulsion welds Optimization of weld current to get nugget diameter mm Range of weld nugget diameters Min 3 500 Max 6 500 Nominal 6 000 rm Note The weld growth curve is generated at predertermined or given constant weld time and weld force referring to 1S014327 2004 sornpas cme Fig 40 Control parameters for simulation of weld growth curve The second procedure is for fully automated simulations to find the optimal weld current for achieving the targeted weld nugget size The targeted weld nugget size can be given as shown in Fig 41 After the simulation and optimization finished the weld current in the data file will be changed to the optimal weld current for reaching the requested weld nugget size Optimization of Weld Current Active pulses to be optimized from No 1 to f1 Select the Procedure for Optimization of Weld Current Generation of weld growth curve with increasing weld current RMS Min Max Increment kA r Optimization of weld current to get nugget diameter 5 000 mm Range of weld nugget diameters Min
153. xplained below File Ini Input Mesh Simulation Batch Run Optimization Weld Planning Results Animations Metallurgy Residuals View 2011 SWANTEC Software and Engineering ApS www swantec com f coya a put Mesh Simulation BatchRun Optimization Weld Planning Results Animations Metallurgy Residuals View Database Help Fig 1 Main menu system File management for opening and saving data files and batch files Prepare or Edit data file with input data for simulation edit the batch file and set up the Preferences Generate and view mesh Run single simulation starting new simulation or continuing from interrupted simulation Run series of simulations in a queue controlled by a batch file that contains a list of data files to be simulated Start automated optimization procedures for optimization of weld current generation of weld growth curve and weldability lobe as well as verification of contact resistance Prepare or edit the Weld Task Description WTD run fully automated weld planning and show the resulted optimal Weld Schedule Specifications WSS Show results of simulation including curves of process parameters evolution of nodal values and report of simulation Show animations of the evolution of parameters including temperature distribution current distribution stress and strain distribution etc throughout the entire welding process Show simulation results of metallurgica
154. zard step 5 to select welding machine and define weld current settings 2011 SWANTEC Software and Engineering ApS www swantec com 34 SORPAS User Manual Version 10 6 Step 6 Welding process time and force settings The welding process time can be defined in each stage including squeeze time weld time hold time off time and idle time The weld time has been set in connection with the weld current The squeeze time is the time used to build up and stabilize the weld force The hold time is for cooling with electrodes sitting on the workpieces The off time is for cooling after electrode ejects from the sheets so electrodes and workpieces can continue cooling down separately The idle time is used mainly for further cooling of electrodes between welds in simulations of multiple welds The weld force can be given in KN or pounds It can also be defined how the weld force is applied from the upper lower or both electrodes A weld force profile or programmable weld force can be set by specifying multiple force steps The force level the force buildup slope and the step time with the same force can be defined to build any force profile Details of the weld force as function of time can also be defined in the general input data editor as described in Section 3 3 3 HE sorpas st si dat Baik e File Input Mesh Simulation Batch Run Optimization Weld Planning Results Animations Metallurgy Residual SORPAS R Edit Input

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