EWI’s structural integrity and modeling team helps manufacturers predict microstructure stress and distortion; qualify joining methods; validate failure criteria; and reduce destructive testing. Several examples are shown in this video, including our innovations for impact simulation software.
Find a condensed list of these simulations below:
- A T-Joint Arc Welding Simulation: A double-sided arc welding was simulated with Goldak’s double-ellipsoidal heat source model.
- Laser-Welding Simulation: In-process rolling technique was developed to control weld residual stresses in laser-welded panels. This simulation was demonstrated with in-process rolling.
- Post-Process Rolling Simulation: This post-process rolling technique was developed to effectively reduce the residual stresses in laser-welded joints.
- Resistant Spot Welding Simulation: An incremental coupled electrical, thermal, and mechanical simulation was conducted to predict the temperature distribution during spot welding. This simulation displayed temperature evolution during the welding process.
- Spot Weld Cross Tension Testing Simulation: Analysis procedures were developed to predict spot-weld failure during cross-tension testing. This data could be used to develop spot-weld failure criteria for full vehicle crash analysis.
- Spot Weld Lap Shear Testing Simulation: Analysis procedures were developed to predict spot-weld failure during lap-shear testing. This data could be used to reduce the number of tests orchestrated during the development of spot-weld failure criteria for full vehicle crash analysis.
- T-Component Impact Simulation: A crash simulation of T-Component including 40 spot welds was conducted to validate the developed spot-weld failure criteria. The validation spot-weld failure criteria will be used for full vehicle crash simulation.
- Adhesive-Joint Strength Prediction: A finite-element based analysis method was developed by EWI to predict the failure mechanism of steel-to-composite adhesive joints. The analysis method was used to qualify the adhesive joint strength for ship applications.
- Additive Manufacturing Simulation: An integrated model was developed to predict the outcomes of the manufacturing process such as levels of residual stress and distortion for laser-additive processes. The model has been used to mitigate the cracking tendency during the repair of aero-engine blades. Temperature and deformation evolution were monitored during the laser simulation.