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

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.

This is why we have evolved our SYSWELD solution. SYSWELD is virtual assessment and validation software designed to support engineering teams as they approach multi-material joining and welding.

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 SYSWELD's new capabilities and benefits, and then explore two case studies of the solution in action.

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 new, evolved version of the ESI 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 the new, evolved version of SYSWELD, we focused 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, we integrated a few key features 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.
 

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.