Software related topics

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

Can I use an absolutely flat tip design for the electrode?

Absolute flat tip of electrode does not exist in reality.

Even if they made the electrode with absolute flat tip by design, after just one weld, the tip face is deformed to have a natural curvature with a radius of R=50mm to R=100mm approximately.

The ISO Standard electrode forms are mostly with tip face curvature R=50mm.

If you design it in the software with an absolute flat tip, it is not possible to build up heat due to the large contact area in the beginning of the welding process.

Can I add coating to a rivet?

Yes, in SORPAS® 2D. joining you also have the possibility to add a coating to the rivet like in 2D. welding.

On how to add coating to the rivet follow these steps

    1. Open the file and go through edit data file.
    2. Select the rivet you want to add coating on.
    3. Under Geometry and Materials find the insert bottom and click on it.
    4. In the inserting window select option “Coating around the Object”.
    5. Then choose the coating thickness and click OK.

Now the coating is added to the rivet.

Add material to the SORPAS® database

Folders in database

When you create new materials, we recommend that you first create a folder in which you place your customized materials. This makes it easier to keep track of what is standard materials and what is your customized materials.

See instruction on how to create materials below.

Variations of standard materials

You can add new materials to the database with your own specifications. This can be useful if you learn that the material properties that you receive from your supplier is a bit different from standard materials.

In order to do this easily, we recommend that you duplicate an existing material from the same type of material as the one you want to create and then change the specifications that are different.

When you duplicate a new Category named “original category name”_1 and a new material named “original material name”_1 are created. You can change the name of both the category and material name. We recommend that you keep the first part of the name as it is – and only change the _1 to something else in order to identify. This makes it easy to keep track of where the data comes from.

Remember to click save when done.

For further instructions please see manual.

New materials based on fully new specifications

When you want to work with totally new materials, we recommend that you send us all the details of the material.

Send the file to us via our support portal.

If you are an active user of SORPAS®, we add the material free of charge.

Need help?

SWANTEC Support Team can help SORPAS users to add new materials to the material database according to the basic material information provided by the user.

The basic material information include:
  • Material name (standard material code, commerical material name, mateerial id number etc.)
  • Material type (low carbon steel, dual phase, TRIP, boron steel etc. for steels, or 5xxx, 6xxx, or 7xxx series for aluminum alloys)
  • Sheet thickness (if material properties different for different thickness)
  • Chemical composition
  • Mechanical properties at room temperature (either data of the flow stress curve or with data for yield strength, tensile strength, elongation at break, n-value)
Contact our support team to receive a detailed Excel file.