SORPAS® 3D.welding

SORPAS® 3D has been developed on the basis of successful applications of SORPAS® 2D on the same concept with easy-to-use graphic user interface (GUI) and straightforward functions for industrial applications of resistance welding.

It is now possible to simulate complex and challenging applications of resistance welding.

SORPAS® 3D Input Wizard has been specially designed for quickly building and operating 3D models, setting up welding parameters, programming movements of electrodes and workpieces similar to production assembly line of resistance welding.

SORPAS® 3D can be quickly learned and easily used by industrial users and welding professionals. To the right is a screenshot of the GUI with the step of Input Wizard for building 3D models.

SORPAS 3D Input wizard step 1 - square nut projection welding
[SORPAS 3D Input wizard step 1] square nut projection welding model

The material database and machine database are directly shared with SORPAS® 2D. Two new libraries have been developed for storing and loading 3D models of hexahedral mesh objects for electrodes and workpieces.

Industrial Applications of SORPAS® 3D welding

Our goal with SORPAS® 3D.welding is to facilitate and support research and development, product design, and welding process optimization. SORPAS® 3D.welding can be used for simulation of complex welding applications such as multiple welds, projection welding, electrode misalignment and rotational movement in seam welding.

Below are some examples of SORPAS® 3D.welding simulations.

SORPAS 3D simulation for 3 spot welds

Multiple welds (Shunt effect)

Resistance spot welding is commonly used for assembly of larger sheet metal components with multiple welds. When spot welding is made one after another, the weld current when making a new weld partly passes through the previously welded spot welds. Due to the current loss through previously welded points, the nugget size of new weld will be slightly reduced. This is the shunt effect. The amount of current loss depends on the distance of the new weld from the welded points.

sorpas 3d model for gap between metal sheets

Spot welding with gap between sheets

It is quite common during the welding production, there may be gap between sheets before starting spot welding, mainly due to the process tolerances in the preceding stamping process, stamping or sheet forming. This will need special process parameter settings to close the gap between sheets before starting the weld current. It can be done by prolonging the squeeze time, slightly increase the electrode force during squeeze time, or by using a preheating pulse with lower current before the weld current.

sorpas 3d model for electrode misalignment

Electrode misalignment

Due to mounting errors or elastic deflection of the weld gun during spot welding, the electrodes are quite often not perfectly aligned to each other. The electrodes may be tilted with a small angle to each other, or may be offside with a small distance between the contacting centers of the two electrodes. The electrode alignment may produce irregular weld nuggets or cause severe expulsions (spatter, splash). SORPAS 3D.welding can simulate the effect of electrode misalignment in all situations.

projection welding model for long-embossment

SORPAS® 3D model for simulation of resistance projection welding with longitudinal embossment.

projection welding with longitudinal embossment

SORPAS® 3D simulation result for resistance projection welding with longitudinal embossment.

SORPAS 3D model for single-sided sheet to tube welding

SORPAS® 3D model for simulation of single-sided sheet to tube welding.

Single-sided sheet to tube welding result by SORPAS 3D.welding

SORPAS® 3D simulation result for single-sided sheet to tube welding.

3D simulation of spot welding and weld strength testing in one go

It is also possible to continue with SORPAS® 3D.testing after completing the welding simulation with SORPAS® 3D.welding. This has made SORPAS® 3D the only software system with simulation of welding process and subsequent weld strength testing with failure mode prediction all in one go.