SYSWELD 2024.0

From Weld Quality to Body Manufacturing & Distortion Engineering, ESI SYSWELD offers a unique computer-aided assessment of material characteristics, residual stresses and distortions by taking into account all the multi-physics that is involved in Welding, Assembly and Heat Treatment manufacturing processes:

• for process feasibility and material characteristic control
• for process security and product performance improvement
• for car body manufacturing and distortion control

ESI SYSWELD 2024, a predictive solution for Welding and Heat Treatment simulation, which includes Visual-Weld, Visual-Heat Treatment and SYSWELD plus CSM solvers.

Today, ESI SYSWELD offers an easy-to-use and robust software package to simulate all the multi-physics involved in the Welding and Heat Treatment processes.

ESI SYSWELD 2024.0 includes:

Visual-Mesh

Visual-Weld & Heat Treatment

Visual-Viewer

Sysweld & CSM Solver

Highlights of ESI SYSWELD

Visual Mesh for Weld

• Based on CAD model and 1D curve a new tool “Batch Weld Bead” has been developed to create automatically shell connected model. The user can select all the curves that represent the weld trajectory and automatically the tool detect the corresponding component to be connected and the type of weld (TJoint, Overlap Joint and Butt Joint). The user can define for each bead the size of the bead and the corresponding mesh discretization.

Visual Weld CSM

• 95% of the Sysweld industrial usages has been migrated inside ESI CSM (Computational Structural Mechanics) solver to strongly improve the performance and the usability by taking the full benefit from CSM platform’s DMP power and capability.
• Many enhancements have been achieved within CSM solver to consider all relevant thermal metallurgical and mechanical phenomena related to welding. It includes 3D solid mesh management and shell mesh management, strong thermal and mechanical contact management and post weld heat treatment
• Visual Weld based on CSM solver is a new easy to use User Interface that allows the user to define the welding process to secure process feasibility and security, to control material characteristics and residual stresses, to keep distortion within specified tolerances, and to improve the performance of the product.
• Un connected mesh management: User can define any contact condition between components and between components and welds in case of un-connected mesh management between weld bead and components. The contact will then assure the thermal and the mechanical continuity. Sticking or sliding contact can be applied.

Spot Weld Rupture

• A new easy to use workflow has been implemented to allow the user to define a spot weld rupture process chain. It provides a streamlined and intuitive workflow to evaluate spot weld process and strength virtually that enables individual engineers as well as cross disciplinary teams to explore, validate and resolve real-world manufacturing and crash CAE process issues in terms of weld process window, quality, and strength.As a result, user can remove the strong dependency on physical-based, non-scalable processes by evaluating the weld quality and strength more efficiently and accurately in the virtual world, while optimizing their welding process and crash CAE prediction.

• The solution is built on advanced chaining of multi-physics spot welding simulation and strength analysis simulation enabling unlimited tryouts of weld parameters & material-thickness combinations.

Visual Assembly

• Assembly simulation to ensure dimension accuracy “distortion control” of assemblies which covers the complete car body manufacturing chain starting from the stamped part to pre-positioning to holding/clamping and finally welding/joining. It also covers large-welded assemblies with thick plates and multi-pass welds, which are common in the shipbuilding industry. Some of the major release highlights are:

  • Enhancement of Contact in Assembly, Improvement of Scan to Mesh, Penetration Check - Pin Locators, Locator penetration improvements

  • Plenty of critical issues are also fixed to improve the usage of the product.

Please refer to the SYSWELD 2024.0 Release Notes for more information and to the Installation Guide for the installation of ESI SYSWELD 2024.0.