Using a Virtual Assessment and Validation Software Solution to Optimize Multi-Material Joining

How SYSWELD is Supporting Engineering Teams in their Approach to Multi-Material Joining and Welding

Multi-material joining can be complex, with different variables influencing the outcome of the process. Modern engineering teams simply cannot afford to rely on guesswork – they need to know they can get the process right the first time, without fail. Not only this, but they need to receive insights fast without compromising on accuracy.

So what exactly does virtual assessment and validation software do, and what are the advantages? Perhaps most importantly, how does it work in practice? This is what we're going to be looking at as we examine the capabilities and benefits, and then explore a case study of a solution in action.

Understanding Virtual Assessment in Welding and Multi-Material Joining

In a simple sense, virtual assessment involves simulating a welding or joining process with a high degree of accuracy. This simulation integrates thermal, mechanical, and metallurgical phenomenon to achieve a comprehensive analysis. Using the data generated by this simulation, engineering teams can gain a deeper understanding of what they are working with.

For example, virtual assessment and simulation can offer information on material characteristics, microstructures, temperature profiles, residual stresses, and distortions in welded structures. All of this is valuable insight for engineers as they seek to reduce time to market and minimize cost.

Time is a constant consideration in the development of a virtual assessment solution. Users need accurate results and insights, but they are also working to a strict production schedule. Therefore, they need to complete simulations with precision and also speed.

This delivers a wealth of benefits to engineers across different project types:

The route-to-market is accelerated, and costs are reduced with a streamlined product development process.
The need for physical prototyping is scaled back, reducing wastage and expense.
Teams gain full control over material characteristics and joining processes, and weld quality is optimized.
Any distortions remain within safe parameters and pre-established tolerances.
The end product achieves better performance levels and extended lifespan.

Sysweld Auto Seam Welding

Accelerating Simulation with Welding Virtual Assessment Software

Now that we know what virtual assessment software can do for a welding and joining project, let's take a look at the specifics of the SYSWELD solution in more detail.

SYSWELD already has a long history, and is deployed by some of the leading industrial organizations around the world. Working with these partners gave us insight into what engineering teams need to achieve from their simulation.

The solution is already able to simulate welding processes such as electron beam, laser, and spot welding, among others. It is also able to simulate a number of heat treatment procedures, including carburizing, carbonitriding, and quenching.

For a new, evolved version of SYSWELD, the focus was on accelerating the simulation process without compromising the accuracy and reliability of results. Traditionally, engineering teams use simulation software to achieve accurate insight, but may experience significant delays in lead time, simply because of the slow pace of simulation.

To overcome this issue, and to reduce the time required for process setting and simulation, a few key features were integrated into the SYSWELD solution:

Automated Machine Algorithms

Automated machine algorithms reduce the meshing time operation, helping teams complete the simulation with greater speed.

Complete Material Database

Users can access the materials they plan to use within the database, rather than needing to input all of this data themselves.

Dedicated Workflow for Process Setting

The solution is made more user-friendly, thanks to intuitive workflows that guide teams through process setting.

Optimized Weld Sequence and Process Plans

Artificial intelligence works to optimize the weld sequence, developing the ideal process for the weld.

Streamlined Process Chains Between Simulations

The solution integrates with other simulations, providing data to be used in spot weld rupture process chains simulation, among others.

Reduced Computation Time

High solver performance reduces the computation time, enabling the swift completion of complex simulations.

All of this means the end user can perform multiple simulations quickly. Then, they can optimize the process parameters and take the right decision ahead of the final weld process. Teams can set the simulation and computation running, leave it overnight, and then see results first thing in the morning. The entire process becomes three to five times faster.

SYSWELD Case Studies: Witnessing the Solution in Action

So that's what to expect from the latest version of SYSWELD.

But let's take a look how One automotive OEM has previously been (and still are) using SYSWELD:

SYSWELD in Action: A Case Study at a Leading U.S. Automotive Manufacturing Plant

Another automotive OEM, this time in the US, needs precise evaluations of the spot welding processes, drawing upon a huge amount of data to deliver reliable results. Not only this, but the simulation and assessment needs to be easily accessible for the technicians and assembly professionals – a complete virtual process chain is required so the specific user can get the insight they need, quickly and reliably.

Predicting Rupture and Plotting Force Displacement

When one of the engineers runs a simulation, the solution takes into account the phase promotion, the plastic strength, and the historical manufacturing data. The simulation predicts spot weld ruptures and also plots the force-displacement (FD) curve, delivering accurate results with speed.

Different temperatures used during manufacturing have a significant impact on the relative strength of spot wells. As there are around 5,000 of these welds across the vehicle, teams need to identify stresses and distortions across each of these welds, and the impact on structural integrity.

Providing Data via a Virtual Process Chain

The virtual process chain ensures that data flows swiftly to where it needs to be. For example, the information produced in the simulation can be fed into the full crash model, helping to deliver even more reliable results during crash test simulations.

The aim here is to connect engineers from different fields and different points within the manufacturing chain, providing a solution that enables them to work together seamlessly on a virtual model.

Using SYSWELD with Other Keysight Tools

At this particular OEM, SYSWELD was not used in isolation. The ADMORE advanced model reduction solution was also applied to the virtual spot weld process chain. Model order reduction keeps the simulation model small and manageable, even when a wealth of different datapoints are analyzed together. As multi-material joining is highly complex, model reduction is a vital step in achieving highly accurate results quickly. This is one of the unique features of Keysight's software.

With ADMORE and SYSWELD deployed together, engineers can optimize other spot weld process parameters, such as the force applied to the electrode, the holding time, pre-heat time, pre-heat current, welding time, and welding current, among other variables, without significantly extending the simulation time.

Explore the Advantages of Virtual Assessment Software for Multi-Material Joining

Seamweld Smooth Chassis Temperature

To learn more about the advantages of the next generation of virtual assessment software in your own multi-material joining and welding processes, it helps to see the simulation for yourself. Watch the full presentation, including all the details from our SYSWELD case studies, right here in our media library.

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