Simufact Engineering GmbH, a developer of manufacturing process simulation software, has released Simufact.Welding for the process optimization of welding applications. The platform is said to be an “easy to use” guide to the layout and test of welding processes, and according to the developer it is the first opportunity for welding specialists and engineers to conduct “virtual process design and optimization … in close relation to production.”

Simufact Engineering’s products also include Simufact.forming for forming simulation, and Simufact.material for the simulation of different technical heat treatment processes. It develops products based on the latest solver technology from well-known software developers, set up in a modular system.

Using Simufact.Welding allows engineers and production planners to time the control of several robots with accuracy, easily modifying welding sequences, speed, heat input, stop times, or fastening devices. Process variables are easy to evaluate quickly by changing the welding parameters, leading to systematic optimization of fusion zones, heat-affected zones, residual stress, and distortions.

The software provides tools for reporting display of distortion, temperature distribution, residual stresses, and curve progression of physical factors on fixed measuring points. It also offers several export interfaces. Most different ways of description — e.g., dynamic cuts through the welding seam, flexible views and detailed x-y-diagrams — allow a quick and efficient analysis of the welding process.

Simufact.Welding allows pre-processing and post-processing analysis with a single GUI, requiring no data conversion and presenting results quickly with simultaneous evaluation. Specific details include the “Weldmonitor” tool that tracks all welding seams in a 2D section; section views of all result values; measuring point diagrams for comparing test welds; and progress indication of calculations, with access to already calculated results during the analysis.

As a production process tool, Simufact.Welding offers an interface to RoboCad, as well as an export interface to robots. Welding paths can be simulated in real speed, direction, and inclination, and the program is capable of tracking different heat sources (Goldak model, cylindrical volume sources, surface heat sources with Gauss distribution, and combinations of these.)

The software’s Dual Solver Technology is optimized for MSC.Marc Solver and IFE WELDSIM Solver.

“Modern industrial welding processes ask for a high degree of process security," explained Simufact managing director Dr. Hendrik Schafstall. "Simufact.Welding supplies information which normally could be gained via experiments only and with an unreasonably high effort – or even not at all. Error sources can now exactly be identified. This permits a structured approach for part and process optimization."