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LOHR Industrie Seam Sim project

D. Turlier, Project manager P. Klein, Technical support M. De Azevedo, V&V A. Wilhelm, Automation
January 2010

LOHR 2010 www.lohr.fr

NX Open What is it?


Collection of Application Programming Interface (API) toolkits that allow for the flexible integration of custom software applications with NX through an open architecture.
Common API Backbone of NX Open Object oriented Supports multiple languages and platforms C++, Java, VB, C# Provides access to the NX Data Model Supported by command record and replay A Journal captures this API Endorsed & active across NX
LOHR 2010 www.lohr.fr 1

LOHR Industrie Seam Sim project

Contents

1. Seam Sim Project Presentation 2. Seam weld LOHR shell element model

3. CAD-CAE process and automation

LOHR 2010 www.lohr.fr

LOHR Industrie Seam Sim project

4 fields of Competence

Car-carriers

Public Transportation

Rail-Road

Logistics-defence

LOHR 2010 www.lohr.fr

LOHR Industrie Seam Sim project

Process Cost Parameters

Number of welds Weld length/throat size One side/Opposite sides welding Intermittent/Continuous seam Partial/Complete penetration

Seam Weld structural assessment is crucial (static, fatigue) Seam Weld FEA no commercial solution for a global structure analysis

LOHR 2010 www.lohr.fr

LOHR Industrie Seam Sim project

Contents

1. Seam Sim Project Presentation 2. Seam weld LOHR shell element model

3. CAD-CAE process and automation

LOHR 2010 www.lohr.fr

Seam Sim project

Seam Sim weld shell element model

Global structure FEA uses shell elements


The mid surfaces of the solid sheets are created using Midsurface feature NX tool ( offset method )

LOHR 2010 www.lohr.fr

Seam Sim project

Seam Sim weld shell element model

Equivalent stress through the weld throat

Element centroid or Element node at the mid-height of the weld throat

LOHR 2010 www.lohr.fr

Seam Sim project

Seam Sim weld shell element model

Through metal sheet crack fatigue analysis


Grid Point Force approach Like in nCodeTM or VerityTM solutions

Structural stress is calculated through the plate thickness using nodal forces and moments

Nodes at the weld leg locations


LOHR 2010 www.lohr.fr 8

Seam Sim project

Seam Sim weld shell element model

Through throat crack fatigue analysis


Fricke approach for root cracking in fillet weld subject to throat bending : linearized structural stress is calculated through the throat thickness in the weld leg plane, IIW publication.

Nodes at the weld leg section locations


LOHR 2010 www.lohr.fr 9

Seam Sim project

Seam Sim weld shell element model

In complex structure, the load path depends on the assembly rigidity


a
The weld shell element will have the same section area than the real weld seam. Correct stiffness for both longitudinal direction and transverse direction Weld element thickness = Throat effective thickness (a)

LOHR 2010 www.lohr.fr

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Seam Sim project

Seam Sim weld shell element model

The idea is to connect the weld element to the metal sheets using NX 1D edge to face connector
RBE rigid body element for node projection (rigid kinematic connection, NX NASTRAN RBE2 element)
MPC multi-point constraint, the projected node is linked with no additional rigidity to the metal sheet element. (NX NASTRAN RBE3 element)

LOHR 2010 www.lohr.fr

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Seam Sim project

Seam Sim weld shell element model

Same technique for other weld joints

LOHR 2010 www.lohr.fr

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Seam Sim project

Seam Sim weld shell element model


Verification Validation

Hexa20 541739 dof

Quad8 1025 dof

Deflexion discrepancy < 6%

Stress Range shell volume

m,w MPa 14,85 14,85

b,w MPa s,w MPa 77,01 91,86 76,86 91,71

Grid point force integration discrepancy < 1%


LOHR 2010 www.lohr.fr 13

Collaborative Project ISCAO

Seam Sim project

Seam Sim weld shell element model

LOHR 2010 www.lohr.fr

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Seam Sim project

Seam Sim weld shell element model

LOHR 2010 www.lohr.fr

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Seam Sim project

Seam Sim weld shell element model

LOHR 2010 www.lohr.fr

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LOHR Industrie Seam Sim project

Contents

1. Seam Sim Project Presentation 2. Seam weld LOHR shell element model

3. CAD-CAE process and automation

LOHR 2010 www.lohr.fr

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Seam Sim project

Seam Sim automation


Weld Assistant Face to face

Weld as solid
Fillet, butt, spot welds Sealing , gluing

Connector
Weld section Parameters

Geometry import

CAD Modeling

Synchronisation Attribute mapping

NX CAD
Idealize

NX CAE
FEM meshing

FEM connectors SIM Boundary Conditions


LOHR 2010 www.lohr.fr

SIM Load

Solving

Post

Seam Sim project

Seam Sim automation


Weld Assistant LOHR Toolboxes C++ programs CAD Modeling

NXOpen API
Block styler

CAD Connector Idealize Idealize Update FEM meshing

- Imprint - Attribute

FEM connectors SIM Boundary Conditions


LOHR 2010 www.lohr.fr 19

SIM Load

Solving

Post

Seam Sim project

Seam Sim automation


NX Weld Assistant
1. first face set (multiple selection) 3. seam cross section parameters, ANSI, DIN, ISO, JIS weld standarts

2. second face set (multiple selection)

Weld as solid body

LOHR 2010 www.lohr.fr

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Seam Sim project

Seam Sim automation

The C++ program


1. CAD connection recipe object (face selection from weld feature) 2. makes the imprints of weld legs

3. attributes are assigned to the imprinted faces

LOHR 2010 www.lohr.fr

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Seam Sim project

Seam Sim automation

NX Idealization: metal sheets and weld solids are idealized to mid-surfaces The C++ program
1. makes the imprints of the mid surfaces 2. connection attributes are transferred to the mid-surfaces
LOHR 2010 www.lohr.fr 22

Seam Sim project

Seam Sim automation

NX Advanced simulation fem


-

geometry synchronization , attribute mapping


manual 2D meshing

The C++ program


makes 1D edge to face connections

LOHR 2010 www.lohr.fr

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Seam Sim project

Seam Sim automation


CAE Advanced simulation Fem update no manual operation

CAD modification (weld update)


1 - Plate parameters 2 - Weld size 3 - Move object

4 - Move face
LOHR 2010 www.lohr.fr 24

Seam Sim project

Seam Sim automation

LOHR 2010 www.lohr.fr

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Seam Sim project

Coming events

LOHR 2010 www.lohr.fr

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Thank you for your attention


LOHR 2010 www.lohr.fr