Processmodeling and Simulation

Using Finite Element (FEM), Finite Volume (CFD) and further numerical methods, processes like welding, coating and forming are simulated at the BIAS.

Thermal forming via plasma beam

Simulations provide here an understanding of the processes which affords a cost-saving process optimization under ideal boundary conditions. Therefore, parameter studies are performed. One example for an effective usage of simulations is the minimization of welding distortions. In contrast to real experiments, a simulation can visualize the stress development in a component or a flow field to investigate the dilution in weld beads.

Parallel weld at a T-connection

This is performed for joining of different materials e.g. aluminium – steel and aluminium - titanium joints considering transformation effects and softening of the microstructure. Furthermore, previous and following process-steps like heat treatment are integratedin the simulation, so that complete process chains can be analyzed.

Besides the development of our own simulation modules, the commercial programs ABAQUS, SYSWELD and CFX are used.

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