In an earlier article I talked in general terms about the benefits of using CAE tools to model the physics of manufacturing processes. In this article I will show a case study example using welding simulation to decide on best strategy for welding a 2-part swing arm together.
The objective is to compare 2 different clamping schemes with 3rd iteration that uses tack welds to hold the parts together. The 2 parts were made of carbon steel, welded along an ~80mm length using arc welding with an estimate energy input of around 2000J per centimetre.
The simulation tool used for this analysis uses a state-of-the-art multi-physics finite element programme as the underlying solver, but has custom user interface that speaks to manufacturing engineer about process flow and not about minutia of an FEA job set up.