Methodology for numerical simulation of the MAG welding process

Digital simulation of welding

Figure 1 - C3 rear crossbar

Figure 2 - Diagram of MAG welding principle

Figure 3 - Physical phenomena and couplings of the MAG welding process

Figure 4 - How PAM-ASSEMBLY works

Figure 5 - Methodology development and application approach

Figure 6 - Illustration of the two methods for modeling material input

Figure 7 - Clamping examples (C3 crossbar)

Figure 8 - Example of a clamping model (C3 sleeper)

Figure 9 - Thermal conductivity models

Figure 10 - Enthalpy models for alpha and gamma solid phases and the liquid phase

Figure 11 - TTT diagrams provided by JMatPro for two austenitic grain sizes (30 and...

Figure 12 - Young&#039;s modulus as a function of temperature and yield strength as a function of temperature and metallurgical phases

Figure 13 - Parameters Qa , ba and Qb of the behavior law for alpha phases

Figure 14 - Parameters Kv and nv of the behavior law for alpha phases

Figure 15 - Thermal deformation curves as a function of temperature and metallurgical phases

Figure 16 - Example of the mesher&#039;s application to a mixed solid-shell mesh (top) and a 100% solid mesh (bottom).

Figure 17 - Final meshing of crossbar and weld seams (solid mesh)

Figure 18 - C3 crosshead sequence file extract

Figure 19 - Example of heat maps during soldering (1,171 s and 1,175 s)

Figure 20 - Example of metallurgical maps at the end of welding, with details of a few beads (martensitic phase, 0-100%).

Figure 21 - Final von Mises equivalent stress map

Figure 22 - Equivalent plastic deformation map at the end of the welding process

Figure 23 - Maximum and minimum main stresses at the end of the welding process

Figure 24 - Distortion analysis: counter-camber angle at the stub axle plate

Figure 25 - Map of displacements along X (crossbar axis) and evolution of center distances OP by OP

Figure 26 - Example of a real assembly, with a gap between the two welded parts, and its currently modeled, gap-free version.