New Release of the Welding Simulation Suite

ESI Group New Release of the Welding Simulation Suite Distortion Engineering V2010 / Sysweld V2010 / Visual Environment V6.5 The ESI Weld Team 10

Date: 13 th of November 2010 Subject: New Releases for the Welding Simulation Suite of ESI Distortion Engineering 2010, SYSWELD 2010 and VISUAL WELD 6.5 Dear valued customer, In this document, you will find a summary of the new releases within the Welding Simulation Suite. We appreciate your continuous interest in our products and services. Best regards, The ESI Weld Team 2 P a g e

CONTENTS The Welding Simulation Suite - Available Packages... 5 The Welding Simulation Suite - Available DVD s... 6 PAM-Assembly and Weld Planner Package... 6 Welding Simulation SUITE 2010 DVD Distortion Engineering... 6 Welding Package... 6 Sysweld V2010 DVD... 6 Visual Environment V6.5 DVD... 7 Visual Mesh V6.5... 7 Visual Weld V6.5... 7 Visual Viewer V6.5... 7 What s New... 8 Weld Planner Package... 8 Welding Package... 8 Enabling Virtual Welding Engineering... 8 More Improvements in Bullet Points... 15 Weld Planner Package (Shrinkage Method)... 15 PAM-Assembly Package (LocaL-global Method)... 15 Welding Package (Transient Method)... 15 Language... 16 Toolbox CD... 16 Users Guides and Getting Started Manuals... 16 Step-By-Step Tutorials... 16 Engineering Guide... 16 Online Manuals... 17 Online Help... 17 More about the Distortion Engineering DVD... 18 3 P a g e

Pre-Computed Examples... 20 More on Post Processing... 20 Visual Viewer Starting from V5.5... 20 Getting More Information... 24 Release Notes... 24 Highlights of the Present Release... 24 The Welding Simulation Solution Information for Research & Development... 25 4 P a g e

THE WELDING SIMULATION SUITE - AVAILABLE PACKAGES The Welding Simulation Suite includes the following packages. What you can do with those packages is described in more detail in the following document. Please contact your local dealer to get a copy. How to achieve your goals Available simulation packages 5 P a g e

Preparation of the CAD model Distortion Engineering Quick evaluation Distortion Engineering Process security Material data management Weld Quality Fabrication details Spot Welding Distinctive Competence THE WELDING SIMULATION SUITE - AVAILABLE DVD S The Welding Simulation Suite includes the following DVD s. PAM-ASSEMBLY AND WELD PLANNER PACKAGE WELDING SIMULATION SUITE 2010 DVD DISTORTION ENGINEERING WELD PLANNER V2.0 Fast Distortion Engineering based on a shrinkage method, including pre-processing, solver and basic post-processing. CAD reading and meshing are done with VISUAL MESH. Advanced post-processing is done with VISUAL VIEWER. PAM-ASSEMBLY V5.0 Precision Distortion Engineering and Weld Quality & Residual Stresses for local models, based on the local-global method, including pre-processing, solver and post-processing. CAD reading and meshing are done with VISUAL MESH. WELDING PACKAGE SYSWELD V2010 DVD The Heat Treatment & Weld Quality Simulation solver including all physics, in particular transformation of phases and mechanics including the effects of phase transformations. CAD reading and meshing are done with VISUAL MESH. The weld simulation is set up with VISUAL WELD. Post-processing is done with VISUAL VIEWER. 6 P a g e

The traditional Graphic User Interface is still available to allow access to functionalities that have not yet been ported to VISUAL ENVIRONMENT. VISUAL ENVIRONMENT V6.5 DVD VISUAL MESH V6.5 VISUAL MESH enables CAD import and meshing. VISUAL WELD V6.5 VISUAL WELD enables the definition of the Welding Process and the solution management. Attention: VISUAL WELD requires the Sysweld solver V2010. VISUAL VIEWER V6.5 VISUAL VIEWER allows Multi-physics Post-Processing with result comparison and synchronized animations of different result quantities. 7 P a g e

WHAT S NEW WELD PLANNER PACKAGE The graphic user interface has been ported to 64 bit windows platforms. A new solver the virtual performance solver has been plugged in. The solver runs in DMP for multiple processors. The speedup is illustrated hereafter. 450 400 350 300 250 200 150 100 50 0 1P 4P 8P 16P 32P TIME (mn) The result file size has been reduced by a factor of 5. WELDING PACKAGE ENABLING VIRTUAL WELDING ENGINEERING A co-operation with SLV Rostock / SLV Munich and the software WeldWare enables you to perform Virtual Welding Engineering. 8 P a g e

WELDWARE WeldWare is a modular welding advisory system, which serves for the calculation of heat procedures in welding. With Weldware you can generate and validate the process parameters you need to perform distortion engineering, weld quality and residual stress analysis for complex structures. 9 P a g e

WeldWare allows to; Calculate schematic welding TTT diagrams according to the chemical composition Calculate microstructure in the heat affected zone depending on chemical composition and cooling time Calculate hardness, yield strength, tensile strength, elongation, reduction of area and impact values in dependence of chemical composition and cooling time Consider scatter of charges during determination of mechanical properties or cooling times Calculate the true material composition in multi-pass welds, pass by pass, depending on base and wire materials, and calculate the properties of the material mix Determine the necessary heat input and pre-heat temperature. This works as well for aluminum, titanium, nickel and (high) alloyed steels Calculate the cooling time in dependence of welding process, welding parameters, pre-heating temperature, joint type and material thickness Once process parameters and properties are validated, the generated data serve as basis for simulations on complex structures. The following tools help to complete the information needed for transient welding simulations. STRAIN HARDENING CALIBRATION TOOL The strain hardening tool helps to generate engineering data, depending on temperature and phases. Data for austenite depending on the carbon content is hard-wired. 10 P a g e

PHASE TRANSFORMATION CALIBRATION TOOL The phase transformation tool helps to calibrate iso-thermal and continuous phase transformations. It makes use of the SYSWELD solver to compute the required data automatically. You need to enter only engineering data. The results, for example a CCT diagram - can be displayed as follows. 11 P a g e

MATERIAL DATA MANAGER The material data manager allows composing a material database for SYSWELD. You deal only with data in Microsoft Excel. Thermo-physical properties of all common steel classes are hard wired. The result is a database in SYSWELD format, including all data necessary to perform transient analysis. NEW GRAPHIC USER ENVIRONMENT TO SET UP AND RUN WELDING SIMULATIONS VISUAL-WELD has been designed with the objective to give you an easy access to more than 100 man-years of experience in welding simulation. Running the SYSWELD solver, VISUAL-WELD offers the best possible combination of user-friendliness and result quality. 12 P a g e

SOLVING HUGE MODELS WITH A DISTRIBUTED MEMORY PARALLEL VERSION IN A REASONABLE TIME FRAME A DMP version is available for Linux computers. It allows solving problems in a fraction of the time, especially larger, more element intense, models. Below you can see an illustration of the speed up over the number of processors. 13 P a g e

Speed Up 10 8 6 4 CPU SYSWELD ELAPSE SYSWELD 2 0 0 4 8 12 16 20 24 28 32 36 Nbr Processors The DMP solver will be available in Windows in the next release of Visual Weld V7.0. 14 P a g e

MORE IMPROVEMENTS IN BULLET POINTS WELD PLANNER PACKAGE (SHRINKAGE METHOD) Separation of components allows a more precise simulation of differences in weld sequences Vastly improved weld sequence definition PAM-ASSEMBLY PACKAGE (LOCAL-GLOBAL METHOD) Multi Pass analysis is now possible Structural stiffeners can be included New sequence manager Distance measurements to the initial structure / defined planes WELDING PACKAGE (TRANSIENT METHOD) The performance of Viscous-plastic post weld heat treatment has been improved There is a collector manager to generate all required collectors Weld trajectories are generated automatically The weld path display has been improved The weld sequence can be displayed There is a possibility to automatically generate reports 15 P a g e

LANGUAGE The language of the software is exclusively English. TOOLBOX CD The Toolbox CD contains Users Guides, Tutorials, and the Engineering Guide. It is delivered together with the SYSWELD CD. USERS GUIDES AND GETTING STARTED MANUALS User s Guides and Getting Started Manuals are available for all elements of the Welding Simulation Solution. These guides are integrated within the software, on the software CD and they are located in the chapter 01_Users_Guides of the Toolbox CD. The User s Guide of the WELD PLANNER and PAM-ASSEMBLY are included in the Distortion Engineering DVD. STEP-BY-STEP TUTORIALS Systematical tutorials are available for most elements of the Welding Simulation Solution. They are situated on the toolbox CD, in the chapter 02_Tutorials. ENGINEERING GUIDE SYSWELD includes an Engineering Guide that covers decades of experience. This is not to be confused with the usual Users Guide. Rather than dealing with the usage of the software, it deals mainly with the translation of real cases into a simulation model. It covers and explains the major simulation engineering knowledge as well as pitfalls related to The Finite Element method applied The simulation engineering ground 16 P a g e

The Engineering Guide shows the most effective and thus cost effective ways to solve Industrial problems. The arrangement of the chapters proceeds in the sequence of a typical study. The Engineering Guide is done in a way that it can be easily read and understood. Pre-condition is a standard engineering education. Need to know how to - you will get the answers From engineers for engineers Including detailed Engineering Guidelines and study specifications / quality control documents The fields covered are Most Important Templates Meshing Material Properties Process Parameters Clamping Computation Post-Processing Simulation Methodologies Exceed Speed-Up Access to the Electronic Manuals and the Online-Help How to get Info from the Manuals Literature Sources FEM Course Theory Installation Tips Microsoft Excel Tools Tools ONLINE MANUALS The SYSWORLD software includes an extended set of electronic manuals. It covers the procedures how to use the software, but not the engineering part of the problem solution. The manuals can be split in manuals dedicated to Heat Treatment, Welding and Welding Assembly, and manuals dedicated to the generic usage of the software. The amount of manuals is huge. Please refer to the chapter 12_Access_E_Manuals_Online_Help in the Engineering Guide, to get access. The customer can print his own set of manuals through Acrobat Reader. The printout covers certainly more than 2000 pages, depending on the manuals chosen. A printed set of manuals can be offered to the customers. Due to reasons of logistics, it is preferred that the user prints his own and individual set of manuals, depending on his needs. PAM-ASSEMBLY includes an online manual. The WELD PLANNER does not include yet an online manual. It is however so easy to use that it appears not mandatory. The User s Guide shows how to use it, it comes with the installation. ONLINE HELP 17 P a g e

The SYSWORLD software includes an extended Online Help. Within the Advisors, you get additional help dedicated for the Advisor Usage. PAM-ASSEMBLY includes an online help The WELD PLANNER does not include an online help it is very easy to use The Microsoft Excel tools do partly include a basic online help they are as well very easy to use. MORE ABOUT THE DISTORTION ENGINEERING DVD On the desktop, after the installation, you will find an orange Icon. Double-click on this icon. You will find the following. Double-click on WeldingDE 2010.0 Start PAM-ASSEMBLY or the WELD PLANNER with double-clicking on the icons. Get more information on the installation, and on how to manage license keys with double-clicking on Readme Welding DE 2010.0. 18 P a g e

Attention: The SYSWELD solver is installed again, even if it has been already installed somewhere else. There is thus no need to set any variables or links. It will just work. Double-click on Documentation. You will find reference manuals, release notes, user s guides and getting started manuals. Alternatively, double-click on Examples. You will find examples and the Weld Planner Getting Started course. The Weld Planner Getting Started Course folder includes a complete course to manage welding distortion engineering with the shrinkage method. In chapter seven is explained how to prepare and import meshes. This is valid as well for the local-global method. For PAM-ASSEMBLY, you will find two tutorials, which cover the block and the cross-section method. You have access to a complete welding distortion engineering simulation solution under one icon. You can manipulate meshes with a professional meshing tool, choose between shrinkage and a local-global method 19 P a g e

depending on your needs, and analyze results in depth with up to date post-processing. Any background information you are looking of is included. PRE-COMPUTED EXAMPLES All software components of The Welding Simulation Solution are delivered with pre-computed examples. Many more examples are included in the engineering guide and in the training courses, as well as in the tutorials. The present examples cover all practical situations. MORE ON POST PROCESSING VISUAL VIEWER STARTING FROM V5.5 VISUAL VIEWER starting from 5.5 has been completely overhauled to provide post-processing dedicated to welding and heat treatment. In the context bar, you can switch between Welding and Heat Treatment, Explicit, and Implicit. If you switch to Welding and Heat Treatment, you will find a graphic user interface, which is as much as possible simplified. It offers only the functionality that is needed. Context bar The following result options are gathered in one icon box: Animation Control Contour Section Cut Iso Surfaces and Lines Model Synchronization Model Difference Result options The GUI looks as follows. 20 P a g e

VISUAL VIEWER 5.5 Graphic User Interface Just double-click on the spectrum or a title the control will pop up. Activation of controls with a double-click Animate the evolution of results on demand 21 P a g e

Animation of results with animation control Compare two model variants, synchronize the display, show the differences in a new window and animate it step by step. Distortion comparison of model variants (the difference of the two models is at the right side) and animation 22 P a g e

Generate a cross section and move it through the model, with many display options. Phase proportions in a cross section Load a result file, display different result types, synchronize the display windows and animate the evolution of results step by step, with individual scaling. Temperature, stresses, distortion and plastic strains synchronized and animated 23 P a g e

Display the evolution of results with graphs. GETTING MORE INFORMATION Evolution of the temperature at a node RELEASE NOTES The release notes are included in the DVD s. HIGHLIGHTS OF THE PRESENT RELEASE Ask your local dealer for this document. It illustrates the highlights of the new release. 24 P a g e

THE WELDING SIMULATION SOLUTION INFORMATION FOR RESEARCH & DEVELOPMENT Ask your local dealer for the 130 page document with all the details. 25 P a g e