Strategies for Fast Structural Welding Simulation

An important step in the production of an exhaust system is the welding process. Problems with hot cracking or exceeded welding distortion tolerances can occur during this process. This decreases the quality and the durability of the components on one hand and increases the manufacturing cost on the other hand.

To prevent that such problems due to welding are not detected until the production stage, where each design change leads to extremely high additional costs, the numerical simulation is applied to evaluate potential risks.

Especially if the welding process problems are induced by the thermal mechanical behavior of the parts an FEM based method can be used to support the manufacturing.

Since some years the numerical welding simulation is applied as a standard method in the Basic Development Exhaust Technology at Eberspächer. Particular trouble with this approach has arisen by the long calculation time of weeks or even months, why this method is hardly usable in the series development. Therefore Eberspächer devises and implements a faster approach for structural welding simulation, which allows achieving results and comparing variants within days.

The possibilities for automation provided by HyperMesh and HyperView are used for the speed-up of mesh preparation, calculation setup and post processing. The transient calculation results in a huge amount of data, which will be further processed with user macros and analyzed to evaluate the hot crack and exceed of tolerances risks.

The Author

Angela Hettel
Eberspächer Exhaust Technology GmbH & Co. KG.