HyperWeld Tutorials

Manufacturing Solutions11.0 Tutorials - HyperWeld

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Manufacturing Solutions 11.0 Tutorials - HyperWeld iAltair Engineering

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Manufacturing Solutions 11.0 Tutorials - HyperWeld

........................................................................................................................................... 1HyperWeld

........................................................................................................................................... 3FSW-0010: Introduction to Friction Stir Welding

........................................................................................................................................... 9FSW-0020: Butt Joint Analysis

Altair Engineering Manufacturing Solutions 11.0 Tutorials - HyperWeld 1


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



FSW-0010: Introduction to Friction Stir Welding

Manufacturing Solutions includes an interface for friction stir welding simulation. This interface provides all thetools to create data for friction stir welding and launch the solver. The FSW interface uses the HyperXtrudesolver to obtain the solution, therefore you will find a lot of similarity between the HyperXtrude and FSWinterface. 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 containsthe mesh, material data, boundary conditions, and other special data. The TCL file contains commands toset process parameters and control the solver operations. These commands are in TCL language. In order tomake this process of generating data files simple and efficient, the following features are embedded in theinterface.

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 versionof HyperMesh that you are running and the name of the file you are workingon.

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

4 Manufacturing Solutions 11.0 Tutorials - HyperWeld Altair Engineering


Pull down menu Located just under the title bar. Like the pull-down menus in many graphicaluser interface applications, these menus "drop down" a list of options whenclicked. Use these options to access different areas of HyperMeshfunctionality.

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

Command Window You can type HyperMesh commands directly into this text box and executethem instead of using the HyperMesh Graphical User Interface.

Utility Menu 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 pagemacros control how a model displays in the Graphics area.

The other macro pages available are QA (contains element checkingmacros), Mesh (contains macros associated with creating and editingmeshes), User (contains macros you create), and Geom (contains macrosrelated to working with a model’s geometry).

The content of the macro menu changes based upon the selected userprofile.

Header bar The Header bar separates the Graphics area from the Panel area. The leftend of the Header bar displays your current location. At this time, you willsee Geometry displayed. The three fields on the right side of the header bardisplay the active user profile, current component collector and current loadcollector. The latter two fields are blank.

As you work in HyperMesh, any warning or error messages also display inthe Header bar. Warning messages appear in green and error messagesappear in red.

The quit button on the rightmost end of the Header bar ends the HyperMeshsession. When you select quit, if changes have not been saved a save fileinformation confirmation message appears so you can save your changesbefore HyperMesh closes down.

Hint You can hold the left mouse button down on top of a panel to see adescription 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 creation and editingof geometry.

The 1D, 2D, and 3D pages contain element creation and editing tools groupedaccording to element type.

The Analysis page contains functions to set up the analysis problem anddefine the boundary conditions.

The Tool page contains miscellaneous tools and model checking functions.



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 thefunction 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 toogeneral 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 Profiles.

3. For Application, select Manufacturing Solutions.

4. Select Friction Stir Welding.

5. Click OK.

Friction Stir Welding Utility Menu

The FSW Utility Menu lists options to import models into HyperMesh, create weld mesh, select and assignmaterial properties, define and apply boundary conditions, define process conditions, and export data files toHyperXtrude.



Buttons in the macro menu fall into two categories:

Shortcuts to native HyperMesh panels

TK popup menus

Import Data

CAD Imports CAD drawing.



HM Imports an HyperMesh file.

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

Select Units Allows you to set the units used 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 databaseand assign material properties to different components. You can alsoview Viscosity/Flow stress graph for a material.

Process Data These macro buttons allow you to define boundary conditions, solutionmonitoring 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 external faces without loads.

Check Duplicate BC Identifies duplicate loads.

Process Data

Parameters Specifies process control parameters.

Extract Points Defines solution-monitoring points. The HyperXtrude solver printsdetailed solution history at these points.

Model Summary Inspects summary data such as number of elements and loads.

Export 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 Datadeck or using a restart file.

Return to Friction Stir Welding Tutorials



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 upthe data for HyperXtrude and solve the problem.

All files referenced in this tutorial are located in the HyperWorks installation folder <install

directory>\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 storeyour 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 ona 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. Assign 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 Profiles.

3. For Application, select Manufacturing Solutions.

4. Select Friction Stir Welding.



Step 2: Select units

1. On the Utility Menu, click Select Units.

A window displays with the option to select 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 Menu, click Create Mesh.

The Create Weld Joint window with icons showing available parametric model’s weld joints display.



2. Click Butt Joint.

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 heightare used to define the tool geometry.

3. Review the default data, and click OK to create the mesh and continue to the Process Parameterswindow.

4. Click OK to accept the default values.

The process parameters are inputted into this window. The process parameters include: temperature ofplates, rotational speed and translational speed of the tool, friction coefficient at the shoulder contactsurface, convective heat transfer coefficient, and the ambient temperature.



5. Continue to select material properties.

6. Under System Materials, select H-13 and AA6063.



7. Click Close.

The mesh generation process completes. The finite element mesh of the weld joint with boundaryconditions displays in the main graphics area.



8. On the Utility Menu, under Process Data, click Parameters.

The first property page on the parameters widget displays the job control parameters. The second pagecontains the process parameters. The third page contains the advanced parameters such as thenonlinear iteration relaxation parameters. The last page allows you to enter additional run controlcommands.

9. Change the Job/Model Name to FSW_0020 and click Update. Click Close to close the dialog.

Step 4: Summarize the model

1. On the Utility Menu, under Process Data, click Model Summary.



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 inHyperXtrude solver data file format.

1. On the Utility Menu, under Export Data, click FSW.

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

3. Save the file as fsw_0020.grf.

4. Click Export.



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, type %hx –I butt_joint.tcl.

HyperXtrude launches and loads the tcl file.

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



Step 7: Inspect materials and process parameters

1. From the Properties menu click Material.

A form 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 Windows, menu click Status.

2. Click View to view the main viewport.



Step 9: Change the background color

1. Click the mesh icon .

2. Select the Graph Opts panel from the Viewport Control Form.

3. Select Background: white.

Step 10: Inspect the boundary edges

1. Click on the BC 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 Viewport Control Form.

5. Deselect all the boundaries and Dismiss the Data View Form.

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 Full.

Step 12: Run the analysis

1. Click Solve. 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 Load Results icon .

2. Click Set All.

3. Click Apply.

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



Step 14: Display color plots of the results

1. Click the Isosurfaces icon .

2. Choose Display: flat and click Apply. The pressure solution is shown. The pressure in the solid domainis equal to zero.

3. Change Color by to Velocity Magnitude.

4. Change Color by to Temperature. Due to the differences in thermal properties of the two materials, theshapes 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 Particle Traces icon .

5. Select the Traces page from the Data View Form.

6. Select Traces Start From: Inflow.

7. Click Launch. 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 Color by magnitude.

3. Click Apply. The velocity vectors are displayed.

4. Clear the Show check box to turn off the display.

5. Dismiss the Data View Form.

Return to Friction Stir Welding Tutorials

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