Dissertations / Theses on the topic 'Sysweld'

Conselho Nacional de Desenvolvimento Científico e Tecnológico
The establishment of manufacturing process with high productivity and quality is a constant requirement of the industrial sector. A possible methodology for carrying on this need of process optimization can be achieved by numerical-computational simulation. Specifically for welding processes, recently developed commercial software has called the attention in both academic and industrial sectors: the Sysweld®. This software has the capacity of simulating different welding processes, including heat source movement, material deposition, transient material properties as a function of temperature, phase transformation and also thermal and superficial treatments. As result, Syweld® is capable of predicting temperature field, residual stress, distortion and phase proportion (microconstituents). However, despite the great possibility of the software usage, it demands an experimental calibration to assure confidentiality on the results. Therefore, within this context, a case study was performed in an automotive component nationally fabricated to delimitate a methodology for carrying out the numerical-computational simulation for the welding process using the commercial software Sysweld®. Simulations were done for the welds made in a part of the rear axle of a hatch car and the results are shown for the temperature field, generated distortion in the part, residual stresses and phase proportion. The thermal results and displacements were experimentally compared to measurements done by thermocouples and three-dimensional table in the partner industry. This comparison led to a poor correlation between numerical and experimental data. In a second stage, a numerical-statistical study was carried out for assessing the parameters influence (gap, thickness, heat source level and clamping system) on the residual stress, maximum displacement and cooling rate between 800°C e 500°C (ΔT8/5). The obtained results are in agreement with technical literature.
O estabelecimento de processos de fabricação cada vez mais produtivos e de maior qualidade é um requerimento constante do meio industrial. Neste sentido, uma das metodologias possíveis para a busca pela otimização de processos é através do uso de simulações numérico-computacionais. Em específico para processos de soldagem, um software comercial de simulação numérico-computacional de desenvolvimento recente vem chamando a atenção por parte do setor industrial e meio acadêmico: o Sysweld®. Este software tem a capacidade de simular diferentes processos de soldagem, incluindo movimento da fonte de calor, deposição de material, as propriedades dos materiais dependentes da temperatura, transformações de fase e ainda tratamentos térmicos e superficiais. Como resultados, o Sysweld® é capaz de predizer campos de temperatura, tensões residuais, deformações e porcentagem de fases (microconstituintes). Entretanto, apesar da grande possibilidade de uso deste software, ele demanda uma calibração experimental para garantir a confiabilidade dos resultados. Com base neste contexto, foi realizado um estudo de caso em um componente automotivo fabricado nacionalmente, de maneira a delimitar uma metodologia de condução de simulação numérico-computacional para fabricação por soldagem no software comercial Sysweld®. Foram realizadas as simulações de todas as soldas do eixo traseiro de veículo do tipo hatch, como resultados foram obtidos o campo de temperatura, as deformações geradas no componente, as tensões residuais e a porcentagem de cada fase. Os resultados térmicos e de deslocamentos foram comparados experimentalmente através de medições realizadas com termopares e mesa tridimensional na indústria, onde não apresentaram boa correlação. Em uma segunda etapa foi realizado um estudo numérico-estatístico sobre a influência de parâmetros (folga, espessura, fonte de calor e sistema de fixação) sobre as tensões residuais, o deslocamento máximo e a variação do resfriamento entre as temperaturas de 800°C e 500°C ( ΔT8/5). Os resultados obtidos ficaram em conformidade com a literatura.
Mestre em Engenharia Mecânica

Presented master thesis deals with computational modelling (simulation) of welding process. Its main goal is to determine the residual stresses and deformations arising after welding. SYSWELD and ANSYS are used for simulation, both based on the finite element method. Specifically, the processes of welding fillet and butt welds are solved. Results from both software are compared with each other and verified by experimental results.

The master´s diploma thesis elaborated as the master's degree M-STG Manufacturing Technology solves surfacing problems in the simulations of surfacing turbine rotors pinot pins. The work was seen as a preparatory work before the real surfacing. Topic commissioned by Siemens Industrial Turbomachinery Ltd. For welding plates test has been used the method of SAW and the base material was identical to turbine rotor material, X22CrMoV 12-1. Additional material was Fluxocord 42. Simulations were carried out in programs SYSWELD and Visual - WELD. The output of the simulation software are temperature and stress fields, material structures and creations of the CCT diagrams at the base material, filler material, and mixed area.

In this master’s thesis there are set down dependencies of distortion of T-joints on the size of heat input and welding speed. Dependencies were found for single- and double-fillet welds, for single- and multiple-pass welding. The computer simulations were carried out in programs Visual-Weld and SYSWELD. The size of the melted zones, stress fields, material structure and hardness of the weld specimens were specified. Simulation results were compared with experimentally detected values.

Numeric simulation welding of the turbine vane and rotor - master’s thesis is ordered by the Siemens Industrial Turbomachinery ltd. company. Simulation welding is done in program SYSWELD. Used welding materials are X22CrMoV12-1 (turbine vane), 30CrMoNiV5-11 (rotor), TOPCORE 838 B (additional material). These are temperature-resistant and fire-resistant welding materials. The SYSWELD program works on the principle of finite elements method. By SYSWELD is done the evaluation of temperature and stress fields and material structure after welding. Here is a part , which deals with computations of welding crevices.

In the Visual - Weld and Sysweld programs, a simplified simulation of the welding process of the turbine rotor made of 27NiCrMoV 15-6 substance was performed. The numerical analysis took place at the equal temperature of preheating and it covered both minimal and maximal percent chemical composition. The simulation proved that the percent deviations of elements in the substance change the speed necessary for reaching of the bainitic structure. Simulation results were verified by a practical experiment. Two weld beads were welded to a base substance by MIG method: one bead at the temperature of 200°C, the other one at the temperature of 300°C, both with the same specific input caloric QS. Both micro and macrostructure of the base substance and TOO was evaluated, and the progression of the hardness was measured as well. The deviations fell within the acceptable 15% range.

Master’s thesis titled Welding of turbine rotor materials discusses evaluation of welding parameters by numerical simulation in software SYSWELD and Visual - WELD. Base material 23 CrMoNiWV 8-8 is welded by submerged arc welding technology. Used flux is F 26G and electrode is flux-cored wire TOPCORE 838 B. Material structures, hardness, values of residual stresses and distortion of weldment for this process are calculated by using the numerical analysis.

The thesis deals with methodology for computational approaches for numerical simulations of welding and heat treatment of aluminium alloys. The thesis describes improvement of the current methodology for metallurgical part of the numerical analysis of welding, which is important mainly for prediction of dimensions of the heat affected zone (and deformations). The improvement was carried out based on CHD diagram that describes precipitation and dissolution of phases during continuous heating. The thesis also describes carried material measurements (measurement of chemical composition, dilatometric tests, tensile tests of several conditions of materials at temperatures up to 500 °C and measurement of aging curves), which allowed to significantly refine analysis results for the alloys EN AW-5083 and EN AW-6082. Based on an evaluation of the measurements, several conclusions were made. They can be useful for creation of material databases of other aluminium alloys. The thesis also describes quantification of dependence between tensile strength and yield strength on the Vickers hardness for different conditions of EN AW-6082. There is also methodology for numerical simulation of the heat treatment process of heat treatable Al alloys in the dissertation. The methodology is completely new approach which has never been published so far. Application of this method is based on user changes of the material database in software Sysweld after relatively easy measurement of aging curves. Therefore, the methodology can be considered as promising for application in industrial practice.

This dissertation thesis deals with the improvement of computational approaches for prediction of residual stresses in welded joints of welded structures in order to ensure greater compliance of the calculated results with the real conditions of welding and heat treatment. The improvement of computational approaches is based on application of elastic-viscoplastic material models which are able (compared with elastic-plastic material models) to take into account the viscoplastic processes ongoing during welding and heat treatment. This leads to more accurate calculated results which enter into further assessment of limit states and directly decide on the safety and lifetime of welded structures. Performed computational and experimental works, confronted with results published in the world, confirm the influence and benefit of application of elastic-viscoplastic material models in the frame of welding and heat treatment numerical analyses. Therefore elastic-viscoplastic material model is further applied in solution of practical project solved by IAM Brno. Solution of this project, whose aim is the development of repair of dissimilar metal welds (without post-weld heat treatment) in Dukovany and Temelin nuclear power plants using "Weld overlay method", has confirmed that application of elastic-viscoplastic material model leads to more accurate calculated results. For this reason the elastic-viscoplastic computational approach will be included into all future tasks of IAM Brno.

碩士
國立臺灣大學
材料科學與工程學研究所
102
In this study, the welding process simulation software, SYSWELD, is used to conduct the simulation of a tungsten inert gas (TIG) welding process using two combinations alloys. The two groups of materials are 316L/ER308/316L and 316L/Incoly82/A508 and all of these materials are widely used in nuclear power plants. In addition, experiments are carried out to support the simulation results. By comparing the shape of weld pools, residual stresses, and displacements of both results, the accuracy of the simulation results can be confirmed. The research is composed of two parts, actual experiments and computer simulations. For the actual experiments, the samples is prepared by outsourcing. After getting sample, using the ruler to measure the displacements of sample’s four edge and the High Speed Hole-Drilling Method is subsequently carried out to measure residual stresses of the sample. After finishing the above procedures, observing the shape of weld pool by metallographical analysis. On the other side, the computer simulation is divided into three steps, modeling, solving, and observing the results. First, finite element method (FEM) model with 15,000 meshes of workpiece is established by using the Visual-Mesh, and the weld bead of workpiece is single grooved with 60 degree. Second, the actual process parameters are input to Visual-Weld and then simulate the welding process by SYSWELD. After solving, simulation results can be displayed on Visual-Viewer for comparing both results. The results of actual experiment and simulation indicate that the both displacement and the shape of weld pool are approximately equal. Through the simulation results, the temperature and stress field can be much more clearly. Therefore, the SYSWELD welding process simulation shows potential for industrial applications.