Welding (SYSWELD)

Welding (SYSWELD) 2025.0 includes:

• Visual-Mesh
• Visual Weld (CSM), Heat Treatment, Weld-Rupture and Visual Assembly
• Visual-Viewer
• Sysweld & CSM Solver
• Pam-OPT Solver
• ADMORE Solver

Keysight CAE's Welding (SYSWELD) 2025 solution offers a unique and comprehensive virtual assessment of material characteristics, microstructure, residual stresses and distortions in welded structures and assemblies. Welding (SYSWELD) addresses different welding processes (arc, electron beam and laser spot welding) and heat treatment processes (carburizing, carbonitriding, and quenching) and considers all relevant phenomena (chemical, thermal, metallurgical and mechanical). Thus, Welding (SYSWELD) allows engineers to be as productive as possible by building the physically realistic virtual structures that drastically reduce the number of prototypes to be built in the development phase while improving the quality and lifetime of the manufactured products. This directly minimizes the time to market and development costs, providing Welding (SYSWELD) customers with a key competitive advantage.

With this latest release,Keysight CAE has enhanced the welding & heat treatment simulation capabilities of Welding (SYSWELD) 2025.0 to secure process feasibility and security, to control material characteristics and residual stresses, to keep distortion within specified tolerances, and to improve the performance of the product.

Welding (SYSWELD): Value Proposition

Welding (SYSWELD) is a predictive simulation chain to verify and to validate the welding quality and product performances by considering joining & assembly effects upfront in the design process allowing you to:

• Reduce the need for physical prototypes,
• Control and optimize material characteristics, joining process and weld integrity,
• Enhance product performance, quality, and service life.

95 % of the Welding (SYSWELD) industrial usages has been migrated inside Keysight CAE CSM (Computational Structural Mechanics) solver to strongly improve the performance and the usability by taking the full benefit from CSM platform’s DMP power and capability. The Physical platform convergence becomes the major step to consolidate on Thermo-Mechanical solver technology platform. It offers inter-operability and combinatory capabilities to enable large Manufacturing solutions combinatory value offer and performance solutions value offer.

Many enhancements have been achieved within CSM solver to consider all relevant thermal metallurgical and mechanical phenomena related to welding. It includes 3D solid mesh management and shell mesh management, strong thermal and mechanical contact management and post weld heat treatment.

Visual Weld based on CSM solver is a new easy to use User Interface that allows the user to define the welding process to secure process feasibility and security, to control material characteristics and residual stresses, to keep distortion within specified tolerances, and to improve the performance of the product.

Unconnected mesh management: User can define any contact condition between components and between components and welds in case of unconnected mesh management between weld bead and components. The contact will then ensure the thermal and the mechanical continuity. Sticking or sliding contact can be applied.

A new easy to use workflow has been implemented to allow the user to define a spot weld rupture process chain.

It provides a streamlined and intuitive workflow to evaluate spot weld process and strength virtually enabling individual engineers as well as cross disciplinary teams to explore, validate and resolve real-world manufacturing and crash CAE process issues in terms of weld process window, quality, and strength.

As a result, the user can remove the strong dependency on physical-based, non-scalable processes by evaluating the weld quality and strength more efficiently and accurately in the virtual world, while optimizing their welding process and crash CAE prediction.

Our solution is built on advanced chaining of multi-physics spot welding simulation and strength analysis simulation, enabling unlimited tryouts of weld parameters & material-thickness combinations.

Visual Assembly

Assembly simulation to ensure dimension accuracy “distortion control” of assemblies which covers the complete car body manufacturing chain starting from the stamped part to pre-positioning to holding/clamping and finally welding/joining. It also covers large-welded assemblies with thick plates and multi-pass welds, which are common in the shipbuilding industry.  

Some of the major release highlights are:

• Enhancement of contact management
• Introduction of new convergence parameters in Visual Assembly
• Plenty of critical issues have also been fixed to improve the usage of the product.

From Weld Quality to Body Manufacturing & Distortion Engineering, Keysight CAE Welding (SYSWELD) offers a unique computer-aided assessment of material characteristics, residual stresses and distortions by taking into account all the multi-physics that is involved in Welding, Assembly and Heat Treatment manufacturing processes:

• for process feasibility and material characteristic control
• for process security and product performance improvement
• for car body manufacturing and distortion control

Welding (SYSWELD) 2024, a predictive solution for Welding and Heat Treatment simulation, which includes Visual-Weld, Visual-Heat Treatment and SYSWELD plus CSM solvers.

Today, Welding (SYSWELD) offers an easy-to-use and robust software package to simulate all the multi-physics involved in the Welding and Heat Treatment processes.

Welding (SYSWELD) 2024.0 includes:

Visual-Mesh

Visual-Weld & Heat Treatment

Visual-Viewer

Sysweld & CSM Solver
 

Highlights of Welding (SYSWELD):

• Based on CAD model and 1D curve a new tool “Batch Weld Bead” has been developed to create automatically shell connected model. The user can select all the curves that represent the weld trajectory and automatically the tool detect the corresponding component to be connected and the type of weld (TJoint, Overlap Joint and Butt Joint). The user can define for each bead the size of the bead and the corresponding mesh discretization.

Visual Weld CSM

• 95% of the Sysweld industrial usages has been migrated inside ESI CSM (Computational Structural Mechanics) solver to strongly improve the performance and the usability by taking the full benefit from CSM platform’s DMP power and capability.
• Many enhancements have been achieved within CSM solver to consider all relevant thermal metallurgical and mechanical phenomena related to welding. It includes 3D solid mesh management and shell mesh management, strong thermal and mechanical contact management and post weld heat treatment
• Visual Weld based on CSM solver is a new easy to use User Interface that allows the user to define the welding process to secure process feasibility and security, to control material characteristics and residual stresses, to keep distortion within specified tolerances, and to improve the performance of the product.
• Un connected mesh management: User can define any contact condition between components and between components and welds in case of un-connected mesh management between weld bead and components. The contact will then assure the thermal and the mechanical continuity. Sticking or sliding contact can be applied.

Spot Weld Rupture

• A new easy to use workflow has been implemented to allow the user to define a spot weld rupture process chain. It provides a streamlined and intuitive workflow to evaluate spot weld process and strength virtually that enables individual engineers as well as cross disciplinary teams to explore, validate and resolve real-world manufacturing and crash CAE process issues in terms of weld process window, quality, and strength.As a result, user can remove the strong dependency on physical-based, non-scalable processes by evaluating the weld quality and strength more efficiently and accurately in the virtual world, while optimizing their welding process and crash CAE prediction.

• The solution is built on advanced chaining of multi-physics spot welding simulation and strength analysis simulation enabling unlimited tryouts of weld parameters & material-thickness combinations.

Visual Assembly

• Assembly simulation to ensure dimension accuracy “distortion control” of assemblies which covers the complete car body manufacturing chain starting from the stamped part to pre-positioning to holding/clamping and finally welding/joining. It also covers large-welded assemblies with thick plates and multi-pass welds, which are common in the shipbuilding industry. Some of the major release highlights are:

  • Enhancement of Contact in Assembly, Improvement of Scan to Mesh, Penetration Check - Pin Locators, Locator penetration improvements

  • Plenty of critical issues are also fixed to improve the usage of the product.

From Weld Quality to Body Manufacturing & Distortion Engineering,Keysight CAE Welding (SYSWELD) offers a unique computer-aided assessment of material characteristics, residual stresses and distortions by taking into account all the multi-physics that is involved in Welding, Assembly and Heat Treatment manufacturing processes:

• for process feasibility and material characteristic control
• for process security and product performance improvement
• for car body manufacturing and distortion control

Welding (SYSWELD) 2023.5 includes:

Welding Solution:

• Visual-Weld 2023.5
• Welding (SYSWELD) Solvers 2023.1
• CSM Solver V44.1.0

Spot Weld Rupture Solution:

• Visual Spot Weld Rupture 2023.5
• Welding (SYSWELD) Solvers 2023.1
• CSM Solver V44.1.0

Heat Treatment Solution:

• Visual-HT 2023.5
• Welding (SYSWELD) Solvers 2023.1

Visual Assembly Solution:

• Visual-Assembly 2023.5
• CSM Solver V44.1.0

Highlights of Welding (SYSWELD)

Welding with CSM Solver

New smart powerful weld solution based on CSM platform: Sysweld solver has been migrated to CSM (Computational structural Mechanic) platform which strongly improve the performance and the usability by taking the full benefit from CSM platform’s DMP power and capability. The inter-operability and combinatory capabilities enable large Manufacturing and Pre-Certification solutions combinatory value offer.

Key functionalities of this new welding advisor:

• New weld solution based on CSM is between 2 to 5 times faster than SYSWELD
• CSM solver offers better scalability than SYSWELD
• Unconnected mesh management between welds and components
• Easy thermal and mechanical contact management
• Sliding to sticking contact auto management based on fusion temperature
• Auto contact pair detection between welds and components and between components
• Smart weld sequence manager
• Smart Excel weld process plan tool
• Auto shell mesh creation tool

Spot Weld Rupture

Spot Weld Rupture: Streamlined Virtual Process Chain to evaluate spot weld process windows and to predict body design rupture considering manufacturing effects. Fully virtual solution that eliminates dependency on physical testing, increases efficiency and improves connection strength.

Key functionalities of this new solution:

• Predictive solution for whatever process lobe and rupture
• Streamline weld process chain
• Computation time saving
• Advanced model order reduction fully embedded in the workflow to perform large process lobe space exploration for faster decision-making
• Allow multi parallel runs for process lobe analysis
• Weld/Rupture simulation compatible with adhesive bounding
• 3 sheets rupture analysis

Visual Assembly

New generation, easy-to-use assembly simulation to ensure dimension accuracy “distortion control” of assemblies which:

• covers complete car body manufacturing chain starting from the stamped part to pre-positioning to holding/clamping and finally welding/joining
• covers large-welded assemblies with thick plates and multi-pass welds, which are common in the shipbuilding industry

Key functionalities:

• New feature for part feasibility analysis
• Integration of quality control feature within assembly context
• Surface cleaning and meshing utility
• Weld bead creation support for non-conform mesh
• Scan to Mesh tool enhancements
• Repositioning using 3-2-1 approach
• Adaptation of new color scheme
• Integration of signed displacement contour
• Separate trade for Assembly

VE 2023.5.1 is mainly targeted to have critical bug fixes for Assembly solution (Visual Assembly) related to contact management, USTART/ part feasibility analysis.