A common method to evaluate the weld quality is by destructive testing to obtain the maximum breaking force in various testing methods (cross tension, tensile shear and peel test etc) and to obtain the failure modes (plug or interfacial failure). SORPAS® 3D.testing can make 3D simulations of all testing methods to predict the weld strengths, such as tensile, shear and peel strengths, as well as the failure modes by simulating fracture of the welded sheets.
The key applications of SORPAS® 3D.testing are the following:
- To evaluate the weld and joint strengths based on the welding simulations with actual welding and joining conditions.
- To provide the weld and joint strengths dependent on actual materials and welding conditions to the subsequent structural and crash simulations.
It is possible to make SORPAS® 3D.testing simulations by directly making the 3D testing model with sheet materials and defined weld points, or by continuing on the results of SORPAS® 3D.welding to include the material properties changed around the weld zone due to heating and cooling during welding. It is also possible to make SORPAS® 3D.testing simulations with results of SORPAS® 2D.welding and 2D.joining simulations via the add-on module of SORPAS® 2D3D.link. Read more about that here.
SORPAS® 3D.testing can combine simulation of resistance welding and mechanical joining with weld strength tests:
- Tensile shear test
- Cross tension test
- Axial tensile test
- Peel (or bending) test
- Torsion test
CAE/CAD engineers need realistic weld strengths to make crash modeling and structural simulations depending on actual materials and realistic welding production conditions. SORPAS® 3D.testing can predict weld strength results based on welding simulations and export results to crash simulation models such as Abaqus and others.
Templates for making 3D models with different testing methods
The SORPAS 3D.testing software has build-in 3D modeling templates for creating strength testing workpieces by defining the geometric parameters. By entering a few parameters for the dimensions and shapes, users can easily create a test workpiece for Cross Tension test, Lap Shear test, Coach Peel test and KSII test.
Below are some examples of weld strength testing simulated by SORPAS® 3D.testing. The simulation results include the weld strengths and failure modes as well as the load-elongation curve with maximum breaking force.