spot weld simulation_sanitized
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Spot Weld Simulation
WB 13
Nov 1, 2010
tpp
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Investigation
Develop a small example model built in WB
DM and WB Mechanical
Demonstrate two approaches to representingspot welds for the example model
1. Spot welds modeled by the point feature in DM
2. Spot welds modeled by line bodies in DM
Compare results for the two approaches and
highlight their advantages and disadvantages
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Approach 1:
Spot Welds By Point Feature Use the point feature in DM to model spot welds
which become beam spiders behind the scenes inMechanical
Advantages Useful automations available for constructing spot
welds in the geometry
Disadvantages
Beam spiders are not visible or accessible
Mesh is typically irregular due to imprinted points inthe welded bodies
Results tend to be stiff and irregular
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Point Feature Spot Welds
Point feature generates spot welds that imprint
vertices in the faces of the guide bodies
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Surface Bodies Only
Geometry in Mechanical does not include any
representation of the spot welds
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Spot Weld Connections
Spot welds are represented by vertex pair
connections
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Mesh with Spot Weld Connections
Imprinted vertices cause the mesh to
be irregular
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Boundary Conditions
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Deformation
Unsymmetric result due to irregular mesh
and beam spiders
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Stress
Irregular stress result
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Element Nodal Forces
Forces due to hidden beam
spiders representing spot welds
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Vibration Mode 1
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Vibration Mode 2
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Vibration Mode 6
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Approach 2:
Spot Welds By Line Bodies and Contacts
Use the point feature in DM to create locations for vertices of linebodies that will represent the spot welds in Mechanical with MPCbonded contact, but ignore bodies with the imprinted vertices
Advantages
Line bodies are accessible in Mechanical to set cross section size andmaterial properties
Mesh for welded bodies is not imprinted with vertices, mesh istypically more regular then when vertices are imprinted
Results are more regular and less stiff than with beam spiders
Results for line bodies that represent the spot welds are available
Disadvantages Line body construction is currently more manual
Contacts have to be generated manually, there is currently noautomations available
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Line Bodies from Points to Represent
Spot Welds
Point are not imprinted into
surface bodies
Can set the cross
section size
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Line Bodies Representing Spot Welds
Can set the material
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MPC Bonded Contact Connections
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Mesh with Line Bodies and Contacts
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Boundary Conditions
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Deformation
Symmetric and smooth result
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Stress
Symmetric and smooth result
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Element Nodal Forces
Symmetric and smooth result
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Element Nodal Forces on Line Bodies
Forces are available for the accessible and visible
line bodies that represent the spot welds
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Vibration Mode 1
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Vibration Mode 2
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Vibration Mode 6
Smooth result
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Summary
Two approaches to modeling spot welds have beeninvestigated, advantages and disadvantages of each havebeen listed
The approach that uses line bodies and MPC contact is
arguably superior Enhancement recommendations for WB DM and WB
Mechanical
Generate line bodies in DM by automations similar to the pointfeature that is current available for spot welds modeling withoutimprinting vertices in the faces of guide bodies
Options to automatically generate connections in Mechanicalbetween vertices and faces to bond vertices of line bodies tofaces of welded bodies