HyperWeld Tutorials

Manufacturing Solutions 11.0 Tutorials - HyperWeld

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HyperMesh 1990-2011; HyperCrash™ 2001-2011; OptiStruct 1996-2011; RADIOSS 1986-2011; HyperView ® ® ® ® 1999-2011; HyperView Player 2001-2011; HyperStudy 1999-2011; HyperGraph 1995-2011; MotionView 1993® ® ® 2011; MotionSolve 2002-2011; HyperForm 1998-2011; HyperXtrude 1999-2011; Process Manager™ 2003-2011; Templex™ 1990-2011; Data Manager™ 2005-2011; MediaView™ 1999-2011; BatchMesher™ 2003-2011; TextView™ 1996-2011; HyperMath™ 2007-2011; ScriptView™ 2007-2011; Manufacturing Solutions™ 2005-2011; HyperWeld™ 2009-2011; HyperMold™ 2009-2011; solidThinking™ 1993-2011; solidThinking Inspired™ 2009-2011; Durability Director™ 2009-2011; Suspension Director™ 2009-2011; AcuSolve™ 1997-2011; and AcuConsole™ 2006-2011. In addition to HyperWorks® trademarks noted above, GridWorks™, PBS™ Gridworks®, PBS™ Professional®, PBS™ and Portable Batch System® are trademarks of ALTAIR ENGINEERING INC., as is patent # 6,859,792. All are protected under U.S. and international laws laws and treaties. All other marks are the property of their respective owners.

Manufacturing Solutions 11.0 Tutorials - HyperWeld

HyperWeld ........................................................................................................................................... 1 FSW-0010: Introduction to Friction Stir Welding ........................................................................................................................................... 3 FSW-0020: Butt Joint Analysis ........................................................................................................................................... 9

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Manufacturing Solutions 11.0 Tutorials - HyperWeld Proprietary Inform ation of Altair Engineer ing

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HyperWeld The following tutorials will give you hands-on experience using the HyperWeld interface.

FSW-0010: Introduction to Friction Stir Welding FSW-0020: Butt Joint Analysis

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FSW-0010: Introduction to Friction Stir Welding Manufacturing Solutions includes an interface for friction stir welding simulation. This interface provides all the tools to create data for friction stir welding and launch the solver. The FSW interface uses the HyperXtrude solver to obtain the solution, therefore you will find a lot of similarity between the HyperXtrude and FSW interface. In addition, it is possible to use the FSW interface to create HyperWeld data decks. Data generated for HyperWeld analysis is organized into two files: GRF and TCL files. The GRF file contains the mesh, material data, boundary conditions, and other special data. The TCL file contains commands to set process parameters and control the solver operations. These commands are in TCL language. In order to make this process of generating data files sim ple and efficient, the following features are embedded in the interface.

The HyperMesh Window

HyperMesh main w indow

There are several main areas in the HyperMesh window: Title bar

The bar across the top of the interface is the Title bar . It contains the version of HyperMesh that you are running and the name of the file you are working on.

Graphics area

The Graphics area under the title bar is the display area for your model. You can interact with the model in three-dimensional space, in real time. In addition to viewing the model, entities can be selected interactively from the area. Graphics

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Pull down menu

Located just under the title bar. Like the pull-down menus in many graphical user interface applications, these menus "drop down" a list of options when clic ked. Use these options to access different areas of HyperMesh functionality.

Toolbar

Located just under the graphics area, these buttons provide quick access to commonly-used functions, such as changing display options.

Command Window You can type HyperMesh commands directly into this text box and execute them instead of using the HyperMesh Graphical User Interface. Utility Me nu

This area contains five pages of macros that perform various functions. The Disp macro page is active and is shaded to signify this. The Disp page macros control how a model displays in the Graphics area. The other macro pages available are QA (contains element checking macros), Mesh (contains macros associated with creating and editing meshes), User (contains macros you create), and Geom (contains macros related to working with a model’s geometry). The content of the macro menu changes based upon the selected user profile.

Header bar

The Header b ar separates the Graphics area from the Panel area. The left end of the Header bar displays your current location. At this time, you will see Geometry displayed. The three fields on the right side of the header bar display the active user profile, current component collect or and current load collector. The latter two fields are blank. As you work in HyperMesh, any warning or error messages als o display in the Header bar. Warning messages appear in green and error messages appear in red. The q u i t button on the rightmost end of the Header bar ends the HyperMesh session. When you select q u i t , if changes have not been saved a save file information confirmation message appears so you can save your changes before HyperMesh closes down. Hint You can hold the left mouse button down on top of a panel to see a description for it in the Header bar.

Page menu

The Page menu allows you to select different sets of functions. The Geom page contains functions having to do with the c reation and editing of geometry. The 1D , 2D , and 3D pages contain element creation and editing tools grouped according to element type. The A n a l y s i s page contains functions to set up the analysis problem and define the boundary c onditions.

The T o o l page contains miscellaneous tools and model checking functions.

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The Post page contains post-processing functions. Panel menu

The Panel menu displays for each page the functions available on that page. You access those functions by clicking on the button corresponding to the function you wish to use.

Friction Stir Welding User Profile HyperMesh is designed to accommodate many different FE solvers. As a result, some panels may be too general for FSW. By selecting the FSW profile, you can work with pre-defined panels that are more specific. To load the HyperWeld user profile: 1.

Launch HyperMesh 10.0.

2.

On the Preferences menu, click User Profil es .

3.

For A p p l i c a t i o n, select M a n u f ac t u r i n g S o l u t i o n s .

4.

Select F r i c ti o n S t i r W e l d i n g .

5.

Click OK .

Friction Stir Welding Utility Menu The FSW U ti l i t y M e n u lists options to import models into HyperMesh, create weld mesh, select and assign material properties, define and apply boundary conditions, define process conditions, and export data files to HyperXtrude.

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Buttons in the macro menu fall into two categories: Shortcuts to native HyperMesh panels TK popup menus

Im po rt Data

CAD

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Imports CAD drawing.


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HM

Imports an HyperMesh file.

FSW

Imports a HyperWeld data deck, including both the GRF and TCL files.

Selec t Units

Allows you to set the units us ed in modeling the problem.

2D Elems

Allows you to control 2d element display.

3D Elems

Allows you to control 3d element display.

Loads

Allows you to control display of Loads.

Lines

Allows you to control display of Lines.

Surfs

Allows you to control display of Surfaces.

Material Data

This macro button allows you to select materials from material database and assign material properties to different components. You can also view Viscosity/Flow stress graph for a material.

Process Data

These macro buttons allow you to define boundary conditions, solution monitoring points, job control parameters, and model summary.

Boundary Conditions

Inspect/Setup BCs

Allows you to view and assign boundary conditions on element faces.

Check Undefined BC

Identifies ext ernal faces without loads.

Check Duplicate BC

Identifies duplicate loads.

Proc ess Data

Parameters

Specifies process control parameters.

Extract Points

Defines solution-monitoring points. The HyperXtrude solver prints detailed solution history at these points.

Model Summary

Inspects summary data such as number of elements and loads.

Exp ort Data

FSW

Saves an FSW data deck and start the HX solver.

HM

Allows you to save the data in HyperMesh format.

Launch Solver

Allows you to Launch HX Solver using the current model, using Data deck or using a restart file.

Return to Friction Stir Welding Tutorials

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FSW-0020: Butt Joint Analysis In this tutorial, you will analyze a friction stir welding of a butt joint. This example shows you how to set up the data for HyperXtrude and solve the problem. All files referenced in this tutorial are located in the HyperWorks installation folder \tutorials\mfs\fsw\FSW_0020 . If you do not know the location of the HyperWorks installation folder on your system, please contact your systems administrator. To work on this tutorial, it is recommended that you copy this folder to your local hard drive where you store your HyperXtrude data, for example, “C:\Users\HyperWeld\” on a Windows machine. This will enable you to edit and modify these files without affecting the original data. In addition, it is best to keep the data on a local disk attached to the machine to improve the I/O performance of the software.

Process The process for analysis using FSW is as follows: 1.

Select the units for the analysis.

2.

Create data files for butt weld joint.

3.

Mesh the computational domain.

4. Ass ign material properties and process conditions. 5.

Export the data files.

6.

Visualize the model in HyperXtrude and inspect material and bc’s.

7.

Launch HyperXtrude. HyperXtrude can also be started from the command line

8.

Post-process the results in HyperXtrude.

Exercise

Step 1: Load the FSW user profile 1.

Launch HyperMesh 10.0.

2.

From the Preferences menu, click User Profil es .

3.

For A p p l i c a t i o n, select M a n u f a c tu r i n g S o l u t i o n s.

4.

Select F r i c ti o n S t i r W e l d i n g .

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Step 2: Select units 1.

On the Utility M e n u , click Select Uni ts . A window displays wit h the option to s elect units for length, velocity , temperature, and stress .

2.

Select the units to use and click OK .

Step 3: Create the butt weld model 1.

On the Utility M e n u , click Create Mesh . The Create Weld Join t window with ic ons showing available parametric model’s weld joints display.

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2.

Click B u t t J o i n t . The geometric parameters for the butt weld joint displays. A weld joint is defined by the length, width, and thickness of the plate geometry. Pin diameter, pin height, shoulder diameter, and shoulder height are used to define the tool geometry.

3.

Review the default data, and click OK to create the mesh and continue to the Proc ess Parameters window.

4.

Click OK to accept the default values. The process parameters are inputted int o this window. The process parameters include: temperature of plates, rotational speed and translational speed of the tool, friction coefficient at the shoulder contact surface, convective heat transfer coefficient, and the ambient temperature.

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5.

Continue to select material properties.

6.

Under System M aterials , select H-13 and AA6063.

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7.

Click Close . The mesh generation process c ompletes. The finite element mesh of the weld joint with boundary conditions displays in the main graphics area.

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8.

On the Utility M e n u , under Proc ess Data , click Parameters . The first property page on the parameters widget displays the job c ontrol parameters. The second page contains the process parameters. The third page contains the advanced parameters such as the nonlinear iteration relaxation parameters. The last page allows y ou to enter additional run control commands.

9.

Change the J o b / M o d e l Na m e to FSW_0020 and click Update. Click Close to close the dialog.

Step 4: Summarize the model 1.

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On the Utility M e n u , under Proc ess Data , click M o d e l S u m m a ry .


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The information on the mesh size, type of elements, boundary conditions, and materials displays.

Step 5: Export data files Next you will save the mesh, material properties, boundary conditions, and process conditions in HyperXtrude solver data file format. 1.

On the Utility M e n u , under Exp ort Data , click FS W .

2.

Use the browser window to select the directory to store data files.

3.

Save the file as fsw_0020.grf .

4.

Click E x p o r t .

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Step 6: Load the model to HyperXtrude 1.

Using a command window, go to the location of your work directory.

2. At the command prompt, t ype %hx –I butt_joint.tcl . HyperXtrude launches and loads the tcl file. 3.

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Click View to launch the main viewport where the geometry is displayed.


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Step 7: Inspect materials and process parameters 1.

From the Properties menu click Material .

A f orm containing the material properties of aluminum displays.

2.

Verify that the material properties are the same as the ones given in butt_joint.grf .

3.

Click Plot to view the plot of temperature and strain rate dependent viscosity and flow stress.

4.

From the Properties menu, click Process . A form displaying the reference quantities opens.

Step 8: Open the main viewport 1.

From the W i n d o w s, menu click Status .

2.

Click View to view the main viewport.

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Step 9: Change the background color 1.

Click the mesh icon

2.

Select the Graph Opts panel from the Viewpo rt Control Form .

3.

Select B a c k g r o u n d : w h i t e .

.

Step 10: Inspect the boundary edges 1.

Click on the B C icon

2.

Click Update to get a list of all the different BCs.

3.

Display the boundaries by selecting one at a time and then click the Redraw button.

4.

Turn off the mesh and Dismiss the Viewpo rt Control Form .

5.

Deselect all the boundaries and Dismiss the Data View Fo rm .

.

Step 11: Inspect the mesh 1.

Leave the boundaries displayed.

2.

Select Grid panel from the Viewport Control Form.

3.

On the Mesh menu, click F u l l .

Step 12: R un the analysis 1.

Click S o l v e. This starts the HyperXtrude analysis. The Ready (displayed in green) button will turn red indicating that the code is busy computing.

2.

Observe the run diagnostics on the screen and wait till the Ready button turns green again. The solution process stops after 25 nonlinear iterations.

Step 13: Post-process the results 1.

Click the Lo ad Results icon

2.

Click S e t A l l .

3.

Click A p p l y .

.

This step loads nodal values of all of the results for post processing. You can also selectively load what you require to optimize the memory requirements.

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Step 14: Display color plots of the results 1.

Click the Isosurfaces icon

2.

Choose Display: flat and click A p p l y . The pressure solution is shown. The pressure in the solid domain is equal to zero.

3.

Change C o l o r b y to V e l o c i t y M a g n i t u d e.

4.

Change C o l o r b y to Temperature . Due to the differences in thermal properties of the two materials, the shapes of the temperature contours in two regions are different.

.

Step 15: Display particle traces 1.

Click the BC icon.

2.

Click Select-all to show all BC faces.

3.

In the Color bar widget, turn off the color bar.

4.

Click the Particl e Traces icon

5.

Selec t t he Traces page from the Data View Form.

6.

Select Traces Start From : Infl ow .

7.

Click L a u n c h . The particle traces are displayed

8.

Click Erase .

.

Step 16: Display velocity vectors 1.

From the Data View form, select the Vectors page.

2.

Set Scale= 10 and enable the check box C o l o r b y m a g n i t u d e .

3.

Click A p p l y . The velocity vectors are displayed.

4.

Clear the S h o w check box to turn off the display.

5.

Dismiss the Data View Form.

Return to Friction Stir Welding Tutorials

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HyperWeld Tutorials

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