焊縫分析sysweld教程簡(jiǎn)介

EngineeringSimulationforIndustrySYSWELD焊接有限元軟件介紹Copyright?ESIGroup,2008.Allrightsreserved.2SYSWELD介紹發(fā)展歷史軟件功能特點(diǎn)軟件原理操作流程及軟件界面軟件應(yīng)用總結(jié)Copyright?ESIGroup,2008.Allrightsreserved.3發(fā)展歷史軟件功能特點(diǎn)軟件原理操作流程及軟件界面軟件應(yīng)用總結(jié)SYSWELD介紹Copyright?ESIGroup,2008.Allrightsreserved.4

SYSWELD軟件擁有將近30年的發(fā)展史，1975年由ESI集團(tuán)法國(guó)法砝通聯(lián)合開發(fā)，主要用來解決焊接修補(bǔ)問題，后來又在此基礎(chǔ)上開發(fā)了熱處理模塊。1997年被ESI集團(tuán)收購(gòu)，2004年開發(fā)了焊接裝配模塊，現(xiàn)在在全球范圍已發(fā)展成焊接、熱處理、焊接裝配模擬的領(lǐng)導(dǎo)者，擁有強(qiáng)大的焊接模擬專家團(tuán)隊(duì)。ESI集團(tuán)焊接熱處理解決方案Copyright?ESIGroup,2008.Allrightsreserved.5ESI集團(tuán)焊接熱處理解決方案Copyright?ESIGroup,2008.Allrightsreserved.6發(fā)展歷史軟件功能特點(diǎn)軟件原理操作流程及軟件界面軟件應(yīng)用總結(jié)Copyright?ESIGroup,2008.Allrightsreserved.7軟件功能1.評(píng)估材料焊接性2.節(jié)省生產(chǎn)成本3.優(yōu)化焊接工藝4.控制卡具位置5.減少試驗(yàn)成本6.改善產(chǎn)品質(zhì)量7.提高使用壽命Copyright?ESIGroup,2008.Allrightsreserved.8應(yīng)用領(lǐng)域SYSWELD應(yīng)用領(lǐng)域非常廣泛，幾乎涉及到各行各業(yè)的焊接工藝，主要有：核工業(yè)鋼鐵航空航天

······汽車工業(yè)造船工業(yè)重工業(yè)列車Copyright?ESIGroup,2008.Allrightsreserved.9軟件特點(diǎn)模塊化設(shè)計(jì)通過向?qū)нM(jìn)行前后處理設(shè)置，操作簡(jiǎn)單方便。充分考慮材料的金相變化或組織轉(zhuǎn)變考慮液固相轉(zhuǎn)變鋼鐵材料晶相轉(zhuǎn)變、鋁鎂合金重結(jié)晶提供多種熱源模型三維錐體高斯熱源，雙橢球熱源，二維高斯熱源等實(shí)現(xiàn)MIG、TIG、電子束、激光等焊接熱源的模擬。提供多種焊接接頭模型包括T型焊、對(duì)接焊、搭接焊可采用殼、實(shí)體、殼-實(shí)體混合單元Copyright?ESIGroup,2008.Allrightsreserved.10軟件特點(diǎn)全面的模擬分析能力幾乎可以模擬任何焊接生產(chǎn)過程中可能出現(xiàn)的問題,為焊接工程師提供新的途徑來研究焊接過程,使他們可以預(yù)測(cè)焊接過程所發(fā)生的一切,從而產(chǎn)生新的設(shè)計(jì)方案。軟件材料庫(kù)包含常用鋼鐵、鋁鎂合金材料，并提供易用的材料生成工具。完善的檢查工具檢查前處理設(shè)置是否正確靈活的授權(quán)方案采用全球著名的軟件授權(quán)解決方案FLEXNetPublisher，可以實(shí)現(xiàn)在局域網(wǎng)上浮動(dòng)使用LICENSE。Copyright?ESIGroup,2008.Allrightsreserved.11發(fā)展歷史軟件功能特點(diǎn)軟件原理操作流程及軟件界面軟件應(yīng)用總結(jié)SYSWELD介紹Copyright?ESIGroup,2008.Allrightsreserved.12Copyright?ESIGroup,2008.Allrightsreserved.13CarbidesdissolutionFerrite+Carbon+Interstitialdissolvedcarbon+Externalcarbides+carbon,tetragonaldistortedgridThemorecarbondissolvedathighertemperature,themoregriddistortionatroomtemperature-Phase-Phase-Phase+Initial,undistortedgrid考慮鋼鐵材料的金相轉(zhuǎn)變Copyright?ESIGroup,2008.Allrightsreserved.14考慮產(chǎn)生塑性應(yīng)變的過程溫度場(chǎng)塑性應(yīng)變的累積

熱源沿著焊接線移動(dòng)

由于溫度梯度的影響，在熱源前端及兩側(cè)產(chǎn)生塑性應(yīng)變

一旦溫度超過某一特定值，之前的材料特性會(huì)全部消失。

真實(shí)的焊接過程移除保留Copyright?ESIGroup,2008.Allrightsreserved.15鋁鎂合金重結(jié)晶Copyright?ESIGroup,2008.Allrightsreserved.16焊接熱源

熱源的定義Copyright?ESIGroup,2008.Allrightsreserved.17裝卡條件完全約束無約束Level變形殘余應(yīng)力生產(chǎn)風(fēng)險(xiǎn)大變形使用風(fēng)險(xiǎn)高的殘余應(yīng)力和塑性應(yīng)變找到最優(yōu)裝卡條件

部分約束Copyright?ESIGroup,2008.Allrightsreserved.18計(jì)算結(jié)果溫度場(chǎng)金相變形應(yīng)力塑性應(yīng)變屈服應(yīng)力Copyright?ESIGroup,2008.Allrightsreserved.19發(fā)展歷史軟件功能特點(diǎn)軟件原理操作流程及軟件界面軟件應(yīng)用總結(jié)SYSWELD介紹Copyright?ESIGroup,2008.Allrightsreserved.20Sysweld自帶網(wǎng)格工具用Visual-mesh生成及檢查網(wǎng)格定義組CAD后處理觀察及提取結(jié)果根據(jù)向?qū)гO(shè)置前處理?xiàng)l件用其它網(wǎng)格工具生成網(wǎng)格求解器自動(dòng)求解SYSWELD工作流程Copyright?ESIGroup,2008.Allrightsreserved.21WorkflowLocal模型計(jì)算保存為L(zhǎng)MDB整體模型結(jié)果影射定義焊接順序和約束條件最終變形焊接工藝ComputationGlobal-VisualLocalModel--PamAssembly-PAM-ASSEMBLY工作流程Copyright?ESIGroup,2008.Allrightsreserved.22操作流程—熱源的定義和校核Copyright?ESIGroup,2008.Allrightsreserved.23操作流程—熱源計(jì)算結(jié)果Copyright?ESIGroup,2008.Allrightsreserved.24操作流程—焊接材料工藝參數(shù)的定義Copyright?ESIGroup,2008.Allrightsreserved.25操作流程—定義結(jié)果的檢查Copyright?ESIGroup,2008.Allrightsreserved.26操作流程—求解Copyright?ESIGroup,2008.Allrightsreserved.27發(fā)展歷史軟件功能特點(diǎn)軟件原理操作流程及軟件界面軟件應(yīng)用總結(jié)SYSWELD介紹Sysweld應(yīng)用Copyright?ESIGroup,2008.Allrightsreserved.29焊接過程模擬About6mmCopyright?ESIGroup,2008.Allrightsreserved.30Whatwillbedone馬氏體變形塑性應(yīng)變屈服應(yīng)力排氣管焊接Copyright?ESIGroup,2008.Allrightsreserved.31RenaultVWBMWBMW汽車Copyright?ESIGroup,2008.Allrightsreserved.32汽車t=2.9st=5.4st=16.4s焊接方向ME1ME2ME3ME4CourtesyAK(GermanAutomotiveWorkingCircle底盤–AlMgSi/AlMgMnCopyright?ESIGroup,2008.Allrightsreserved.34CourtesyAK(GermanAutomotiveWorkingCircle)底盤–AlMgSi/AlMgMn電子束焊接

航空航天工業(yè)Copyright?ESIGroup,2008.Allrightsreserved.36大連交通大學(xué)提供列車轉(zhuǎn)向架焊接后變形釋放裝卡后變形Copyright?ESIGroup,2008.Allrightsreserved.37蒸汽輪機(jī)裝配HPpartIPpartLPpart長(zhǎng)度/直徑:大概4mCourtesy?KODAPOWERa.s.Copyright?ESIGroup,2008.Allrightsreserved.38實(shí)驗(yàn)對(duì)比位置計(jì)算變形量

[mm]測(cè)量變形量[mm]A-0,85-1B-8,80-7C-1,92-2CBA應(yīng)力變形裝配變形分析Copyright?ESIGroup,2008.Allrightsreserved.40汽車Copyright?ESIGroup,2008.Allrightsreserved.41汽車Copyright?ESIGroup,2008.Allrightsreserved.42GlobalModel10m4m船舶焊縫總長(zhǎng)120m

Copyright?ESIGroup,2008.Allrightsreserved.43船舶Copyright?ESIGroup,2008.Allrightsreserved.44船舶44造船業(yè)（CTC）的實(shí)例與驗(yàn)證ToolbarsOutputConsoleOriginalpositionMeasureddistortionPredicteddistortion實(shí)際變形SYSWELD模擬結(jié)果對(duì)比圖造船業(yè)的應(yīng)用實(shí)例(CourtesyCTC)Copyright?ESIGroup,2008.Allrightsreserved.45機(jī)車及軌道交通Copyright?ESIGroup,2008.Allrightsreserved.46磁懸浮列車梁:北美重工9個(gè)零件,40條焊縫Copyright?ESIGroup,2008.Allrightsreserved.47磁懸浮列車梁:北美重工X+Z+Y+最小:-5.75mm最大:4.3mm整體變形9個(gè)零件,40條焊縫在普通計(jì)算機(jī)上，大概1小時(shí)高級(jí)應(yīng)用點(diǎn)焊、多道焊及焊后熱處理Copyright?ESIGroup,2008.Allrightsreserved.49高級(jí)焊接工程模擬多道焊Copyright?ESIGroup,2008.Allrightsreserved.50Copyright?ESIGroup,2008.Allrightsreserved.51Copyright?ESIGroup,2008.Allrightsreserved.52

焊后熱處理回火后回火前500℃回火一段時(shí)間拉應(yīng)力減少Copyright?ESIGroup,2008.Allrightsreserved.53點(diǎn)焊Copyright?ESIGroup,2008.Allrightsreserved.54點(diǎn)焊(熱-機(jī)械