3D Case 4 – Peel Strength test of weld nugget

You have to test a lot of different parameters to find out if the formed nugget is acceptable for a certain application. Very often, welding engineers investigate the parameters related to the mechanical properties of the nugget.

In order for you to to measure the mechanical properties of the nugget, you can use different mechanical tests, such as peel strength test, tensile strength test, cross tension test, hardness measurements etc. These tests can help you to evaluate if the weld nugget has an acceptable strength for the application.

SORPAS® 3D.testing can help to evaluate the weld strength based on simulations with actual welding and joining conditions. SORPAS® 3D.testing has also integrated standard templates for workpieces which makes it easier for the you to set up the welding design.

In this tutorial you see how to make a welding simulation and how to make a Peel strength test of the welded workpieces.

This tutorial demonstrates how to build a model with one spot weld and test the weld strength of the nugget. Also, it shows how to add testing tools to the workpieces. To demonstrate this case simple, no change of materials and process parameter has been made, we use default settings.

The example provides an excellent overview of building a model and making weld strength testing. It demonstrates how to build a model, adding contact interface, and adding testing tools.

Peal-strenght-test-model
Peal strenght test model
Plug-failure
Plug-failure

3D Case 3 – Cross Tension Strength Testing

A lot of different parameters has to be tested regarding if the formed nugget is acceptable for the certain application. Parameters welding engineers often investigates are the mechanical properties of the nugget. To measure the mechanical properties of the nugget, different mechanical tests are used such as tensile strength test, cross tension test, hardness measurements etc. These tests can help to evaluate the weld nugget has an acceptable strength for the certain application. With SORPAS 3D testing it can help to evaluate the weld strength based on simulations with actual welding and joining conditions. SORPAS 3D testing have also integrating standard templates for workpieces which makes it easier for the user to set up the welding design. In this following tutorial it will show how to make a welding simulation and how to make a Cross tension strength test on the welded workpieces.
This tutorial demonstrates how to build a model with one spot weld and test the weld strength of the nugget. It shows how to add testing tool to the workpiece. To demonstrate this case simple, no change of materials and process parameter is done, we use default settings.
The example provides an excellent overview of building a model and doing weld strength testing. It demonstrates how to build a model, adding contact interface and adding testing tools.
More information about Weld Strength Test is in the help menu, -> Weld Strength Test.

Cross Tension Testing Model
Cross Tension Testing Model
Cross tension strength testing animation
Cross tension strength testing animation

3D Case 2 – Tensile Shear Strength Testing

A lot of different parameters have to be testted regarding if the formed nugget is acceptable for the certain application. Parameters welding engineers often investigates are the mechanical properties of the nugget. To measure the mechanical properties different mechanical tests are used such as tensile strength test, cross tension test or hardness measurements. These tests can help to evaluate the weld nugget has an acceptable strength for the certain application. With SORPAS 3D testing it can help to evaluate the weld and joint strength based on simulations with actual welding and joining conditions. SORPAS 3D testing have also integrating standard templates for workpieces which makes it easier for the user to set up the welding test conditions. In this following tutorial it will show how to make a welding simulation and how to make a tensile test on the workpieces.

This tutorial demonstrates how to build a model with one spot weld and test the weld strength of the nugget by Tensile shear strength test. It shows how to set up the testing tools on the workpieces. To demonstrate this case simple, no change of materials and process parameter is done, we use default settings.

The example provides an excellent overview of building a model and set up for testing tools. It demonstrates how to add objects such as electrodes and workpiece, adding contact interface and adding testing tools for the workpieces.

The following steps of this tutorial: Model instructions -> Adding contact interface -> Connecting the welding machine -> connecting to the weld testing tools -> Run simulation -> Results.

3D Tensile Shear Stress Testing Model
3D Tensile Shear Stress Testing Model
Zugscherfestigkeitstest
Tensile Shear test

2D Case 1-3 – Automated weld planning

The right weld parameters can take a lot of time. Though, simulation can reduce this time significantly. SORPAS® provides an easy function to find the optimized weld parameters for your weld task.

This tutorial demonstrates how to use the automated weld planning function Weld Task Description (WTD) is used to give you the optimized weld parameteres.

The automated weld planning function predicts the optimal welding procedure specification including optimal weld current, weld force, weld time, and hold time, according to user defined Weld Task Description (WTD). This function helps to find the optimal welding conditions in cases where new design has been chosen but haven’t found a welding profile.

You can use the WTD function in several ways which are shown in this tutorial.

Case 1: 3 sheets combination, using default welding condition. This means all welding process parameter are set to zero and the simulation makes a full optimization of the weld force, current, and weld time based on standard settings.

Case 2: 3 Sheets combination, using specified welding parameters. The “Profile” function is used to specify a welding profile to further optimize the process parameters.

 Case 3: 3 Sheets combination, using preferred parameters condition. The welding profile from case 1 is used but now the weld force is restricted to the machine’s limit.

2D Case 1 setting
2D Case 1 setting
2D Case 2 profile
2D Case 2 profile

3D Case 1 – Creating a 2-sheet spot weld model

This tutorial demonstrates how to build a 3D model with one spot weld and 2 sheets. To demonstrate this case simple, no change of materials and process parameter is done, we use default settings.

The example provides an excellent overview of building a model. It demonstrates how to build a model and adding contact interface.

02 - 3D_spot_weld_model
3D spot weld model
3D_spot_weld_peak_temperature
3D spot weld peak temperature

Knowledge base

We want it to be easy to start with SORPAS® and to update your knowledge about SORPAS®.

Therefore, we have built this knowledge base. The knowledge base is divided up into

  • Training book – look for topics related to how to work – target group “users”
  • FAQ – most common questions – target group “new users or potential users”
  • Tutorials – tutorials for both 2D and 3D to show specific build of models

Should you have questions that are not listed in this section, please contact us here.


SORPAS® shows a zero-nugget size

If SORPAS® shows a zero-nugget size it may be because the workpiece by mistake has been defined as an electrode. Because SORPAS® calculates nugget size between workpieces and not between electrode and workpiece, a zero-nugget size is the result. To solve the zero-nugget size in this case:

  1. Mark the workpiece with the wrong definition. In the “Object type and material” change the definition of the workpiece from electrode to workpiece.

SORPAS® doesn’t show a nugget size

When welding dissimilar materials together, like aluminium and steel, normally, only the aluminium sheet melts and no melting of the steel sheet occurs. In this case, you can show the weld nugget size with two options.

  1. Go to “Preferences”, check the “Nugget Size at Interface” and set the slider at “Larger”
    This shows the final nugget results.
  2. In the “Input Wizard Step 7”, set the “Targeting weld nugget size” at “Max”.
    This makes the reference nugget size from the side with larger melting area. This must be done before “Weld planning”.

Validation of SORPAS® Simulations

Many factors influence the simulation results.

In order to minimize the amount of work that users have to do to verify the highly dynamically coupled numerical models and their interactions with the input conditions, we have already made a lot of verifications and validations of all models with lab tests and user feedback. Many numerical factors essential for welding and joining simulations are already trained and preset for general welding and joining applications. This is why SORPAS® can quickly produce good simulation results with first built simulation models.

However, it is always helpful to improve the simulation accuracy by checking further in details of the practical data especially related to individual welding applications.

In general, there are three most important ones that need to be verified for improving the accuracy of simulations.
  • Check the material properties
  • Check the geometry of electrode tip at working conditions
  • Check the numerical factors
More details are described in the attached document Check Scheme.

How to minimize errors in simulations?

In order to minimize the risk of errors in the simulation, we recommend that you check carefully the following points to see if they are correct before pressing “Start simulation”:

Geometric models and dimensions

  1. Sheet thickness
  2. Coating thickness
  3. Electrode shape / bulk diameter / tip diameter
  4. Electrode tip face curvature

Material data

  1. Sheet material
  2. Coating material
  3. Electrode material

Welding machine and process parameters

  1. Type of current /AC / DC
  2. Weld current
  3. Weld force
  4. Weld time
  5. Pulses