Making multipass welding simulations more robust

I am running multipass welding simulations. In the second or later welding steps, I frequently run into trouble with large deformations and elements turning inside-out, especially in the previous welding beads and the component material below the welding. Cause is obviously the low flow stress of the material at high temperature. Any good ideas for strategies on how to prevent simulations from crashing? Element deletion works, but the results are not satisfactory regarding stress results (see the image for an example).

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0 QW over 1 year ago

Hi Koen,

We would first discourage you from the element deletion, as these often lead to other problems.

To avoid inside-out elements one should always check the reached peak temperature in the simulation and compare it to the real data. If there is a large deviation inbetween, you have to adjust the heat source dimensions or efficiency etc. first to make them match each other. This is so-called the calibration of the heat source and should always be done in a purely thermal simulation. After the heat source is calibrated, you can switch to a thermomechanical simulation to evaluate the distortions and other results.

Please find in the attachment a tutorial about how to do the calibration based on some examples.

Best regards,

Qi Wang

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Heat_source_calibration_2022_public.pdf
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0 QW over 1 year ago

Hi Koen,

We would first discourage you from the element deletion, as these often lead to other problems.

To avoid inside-out elements one should always check the reached peak temperature in the simulation and compare it to the real data. If there is a large deviation inbetween, you have to adjust the heat source dimensions or efficiency etc. first to make them match each other. This is so-called the calibration of the heat source and should always be done in a purely thermal simulation. After the heat source is calibrated, you can switch to a thermomechanical simulation to evaluate the distortions and other results.

Please find in the attachment a tutorial about how to do the calibration based on some examples.

Best regards,

Qi Wang

Attached Files (1)

Heat_source_calibration_2022_public.pdf
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