焊接sysweld 分析

Study presentation Methodology Results Conclusion
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Study presentation
Study presentation
Deformable rear crossmember
New Citroën C3 Deformable rear suspension crossmember Assembly of 20 parts by GMAW welding 84 welding joints (total length 5 m)
Martensitic phase after welding Example of thermal cycle (bead 2092)
1039 s
1042 s
1044 s
1046 s 11Hale Waihona Puke Baidu
Results
Mechanical results
Residual stresses (on parts)
Von Mises
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Methodology
Methodology
General
Input data : shell mesh of the assembled parts + process data
The original shell mesh, used for the mechanical strength computation, is provided by the design team The process data includes welding sequence, electrical parameters, clamping conditions…
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Methodology
Crossmember Model
Welding sequence and clamping conditions are as close as possible to reality
Clamping conditions (fully clamped nodes)
Welding process includes 5 steps
Wheel Damper Coil spring GMAW Welding Weld joints Clamping
Crossmember
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Study presentation
Simulation objectives
• Decrease development delay and cost : Simulation allow to find quickly the best welding sequence Solution : numerical simulation of distortions with PAM Assembly (Simplified localglobal method) or SYSWELD (global transient method) • Increase quality : Residual stresses and material properties after welding can be taken into account during design phase Solution : numerical simulation of residual stresses with SYSWELD (global transient method) To conciliate both objectives, we choose to perform global transient simulations with SYSWELD. A specific methodology was developed to obtain good results with better delay on our industrial parts.
Material properties are essentially provided by JMatPro Software
This solution was validated in PSA in 2009 on Welding and Heat treatment steels
The complete model is written automatically by specific PSA tool Shell mesh (design mesh) Process data
380 MPa
Max. Principal stress
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Results
Mechanical results
Distortion analysis after welding and clamping removal
Norm of displacement (deformed shape x 10)
Step 2
Step 3, 4, 5
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Results
Results
Thermal and Metallurgical results
The total analysis time is 4000 s (1600 s for welding stage). The time step is about 0.2 s during each welding step.
PSA Tool
Material Data (JMatPro) SYSWELD Model with solid mesh (*.dat, *.asc)
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Methodology
Crossmember Model
Meshing with Visual Mesh + internal tools to create weld lines (3D solid + 1D/2D for weld lines and thermal convection) 200 000 finites elements and 145 000 nodes Trajectory Weld lines Reference Deposited material
L1
L2
L1 and L2 length evolution during welding process
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Conclusion
Conclusion
PSA applies welding simulation on complex industrial cases
Specific methodology and automatic procedures were developed to build our numerical model more efficiently and quickly
Welding simulation applied to rear crossmember of automotive vehicle P. Bristiel, PSA Peugeot-Citroën
La Garenne-Colombes Technical Centre 19/05/2010
Summary
Real bead
Modeled bead
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Total solving time is +/- 4 days with new DMP solver (4x2 procs)
Results are consistent with observations (distortions, residual stresses)
Future developments : improvement of meshing (finer mesh on beads), taking into account of the real distance between components…
Initially, all components are fully separated. The assembly is done progressively by the beads.
Final assembly Arms assembly Crossmember assembly
Step 1