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Risultati finali
The Assembly Sequence Planning tool (ASE= Assembly Sequence Evaluator) will assist the engineer in planning the assembly and welding operations to build up big steel structures more efficiently. ASE contains a graphical user interface capable to access an Assembly environment and a Weld Plan environment. In the Assembly environment an Assembly Tree will be generated to define the hierarchical assembly order of the work piece. The assembly order and the geometry of the workpiece parts are given by imported files that represent the ideal, original CAD geometry of the work piece. In the Weld Plan environment, a planning tree will be generated which contains one or more Plan nodes for each assembly.
Each plan enables the user to analyze whether the distorted or non-distorted elements can be assembled. The user can create paths for setting up elements and modify end positions of elements of the assembly in order to make distorted elements fit together. Each Plan node in the Plan Tree can have a Weld Sequence node, which contains the sequences of welds, and tack welds with their start, stop and delay times. The user can change the sequence of welds of the selected assembly and can export the assembly to the distortion analysis tools. Using the functionalities of ASE the user is able to minimize distortion by rearranging the welding sequences and aiming to find the optimal assembly sequence at minimized distortion.
Special visualisation tools which are integrated as part of ASE will assist the engineering tasks.
The Virtual welding tools provide a unique platform to predict distortion, stress, and strain in welding engineering and process design. The suit of tools consists of XML-based user interfaces to describe the simulation project generator, and to transfer the work piece geometry (CAD file) and the WPS data (welding process specifications) into the simulation environment.
The simulation environment contains simulation models for laser welding and MAG welding of steel as well as for MIG welding of aluminium constructions. Key parts of the simulation platform are the mesh grid generator, the heat source modeller, the FEM simulation based on a local/global approach, and an FEM output interface. The computation of the heat source will simulate the fluid dynamics of the weld pool and pass thermal data of the molten pool to the FEM simulation for subsequent use as boundary conditions in the thermal-mechanical analysis. The FEM based simulation tool is using the local/global approach. The principle is to compute stresses and strain on a local model and to transfer it to the global model to compute distortions on large structures. Special goal of the research work was to develop models for reducing computing time. Therefore, two alternative modelling approaches have been developed.
The basic idea of the first approach is the reduction of the model size in the direction transverse to the welding line. The second approach is based on a ''moving refinement''. This technique allows a mesh refinement only around the present heat source position on the work piece.
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