TY - JOUR
T1 - One modified FE-model to simulate the process chain of forming and welding
AU - Zaeh, Michael F.
AU - Roeren, Sven
PY - 2005
Y1 - 2005
N2 - This paper presents a possibility of creating a virtual process chain consisting of forming and welding. Independent of any manufacturing process, a variable Finite Element model is introduced. This model can be an input for more than one simulation by means of the Finite Element Method (FEM). The process chain forming and welding is chosen to demonstrate the need and the importance to simulate a process chain in comparison to a single process simulation. Each simulation has its own specifications and intentions. Therefore, an FE-model for a forming simulation is different from a model for a welding simulation. In this paper a way is shown how to keep the model and the results of a forming simulation for the succeeding simulation of welding. The results of the forming simulation remain as an initial state in the welding simulation. Thereby, a spring-back behaviour can be modelled. A few adjustments have to be done to satisfy the specifications of the welding simulation. The used material for the integrated simulation is a DC 04 steel. Therefore, metallurgical phases must be considered to achieve sufficient results. For reasons of further industrial applications commercial FE-solvers are used for calculations. The method of integration is applied to different examples. The verified results are presented and discussed. The simulated transient distortional behaviour of a formed and welded part is presented and compared to a mere welding simulation. A significant improvement of the distortion as a result of the welding simulation is reached by consideration of a previous forming simulation.
AB - This paper presents a possibility of creating a virtual process chain consisting of forming and welding. Independent of any manufacturing process, a variable Finite Element model is introduced. This model can be an input for more than one simulation by means of the Finite Element Method (FEM). The process chain forming and welding is chosen to demonstrate the need and the importance to simulate a process chain in comparison to a single process simulation. Each simulation has its own specifications and intentions. Therefore, an FE-model for a forming simulation is different from a model for a welding simulation. In this paper a way is shown how to keep the model and the results of a forming simulation for the succeeding simulation of welding. The results of the forming simulation remain as an initial state in the welding simulation. Thereby, a spring-back behaviour can be modelled. A few adjustments have to be done to satisfy the specifications of the welding simulation. The used material for the integrated simulation is a DC 04 steel. Therefore, metallurgical phases must be considered to achieve sufficient results. For reasons of further industrial applications commercial FE-solvers are used for calculations. The method of integration is applied to different examples. The verified results are presented and discussed. The simulated transient distortional behaviour of a formed and welded part is presented and compared to a mere welding simulation. A significant improvement of the distortion as a result of the welding simulation is reached by consideration of a previous forming simulation.
KW - Modelling of weld phenomena
KW - Simulation of a process chain
KW - Thermo-mechanical FE-simulation
KW - Transfer of stresses
UR - http://www.scopus.com/inward/record.url?scp=14644435075&partnerID=8YFLogxK
U2 - 10.1002/srin.200506002
DO - 10.1002/srin.200506002
M3 - Article
AN - SCOPUS:14644435075
SN - 1611-3683
VL - 76
SP - 235
EP - 239
JO - Steel Research International
JF - Steel Research International
IS - 2-3
ER -