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:
- Mark the workpiece with the wrong definition. In the “Object type and material” change the definition of the workpiece from electrode to workpiece.
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.
- Go to “Preferences”, check the “Nugget Size at Interface” and set the slider at “Larger”
This shows the final nugget results.
- 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”.
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.
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
- Sheet thickness
- Coating thickness
- Electrode shape / bulk diameter / tip diameter
- Electrode tip face curvature
- Sheet material
- Coating material
- Electrode material
Welding machine and process parameters
- Type of current /AC / DC
- Weld current
- Weld force
- Weld time
The recommended computer specifications are as follows:
Type of computer: Server computer / desktop / laptop
Operation system: Windows 7 / Windows 8 / Windows 8.1 / Windows 10
System architect 64-bit system (SORPAS® 2D runs on both 32 and 64 bit, but SORPAS® 3D runs only on 64-bit)
Processor speed: 3 GHz or higher
Number of cores: 4 cores or more especially for SORPAS 3D
RAM: 8 GB or higher
Hard disk free space: 50 GB or higher
Export of data to LS-Dyna
You can export your simulation results from SORPAS® 3D into LS-Dyna.
Go to: “File/Export/Results to LS-Dyna
Export of data to DynaWeld
You can export your results from SORPAS® 2D into DynaWeld.
The interface enables you to export process simulation results from SORPAS® and continue the simulation with DynaWeld.
Choose “File/Export to DynaWeld”
Export of data to Abaqus
You can export your simulation results from SORPAS® 3D into Abaqus.
Go to: “File/Export/Results to Abaqus