Step by

Step on
Butt Joint
Welding
(With Table)
Process Flowchart

Start

Geometry
and Mesh
Geometric
Properties

Material
Properties

Contact
Properties

Toolbox

Initial
Condition

Boundary
Condition

Loadcases

Jobs

End
Geometry
&
Mesh
1. Length unit. The length unit option enable us to change the standard unit used
for distance. Any measurement or distance related formula will be dependent on
the selected length unit. For this simulation, the millimeter unit is selected

This drop-down menu will

enable us to change which
unit to be used

2. Grid. It is helpful to set the grid which suits the dimensions on the parts. The grid
can be edited to display the number of points and distance between them. ds

1. Tick the Grid box.

Click on edit to edit the
grid

Center axis

2. Number of points on the x and

y axis. The negative values
indicate points before the center
axis. The third number shows the
distance between each point

Option to change
3 between dots and lines
for the grid

For this simulation, the grid is always edited when drawing different parts to
make dimensioning easier.
3. Geometry and mesh. The parts used in the simulation needs to be created first
using geometry and mesh

Geometry and
mesh drop-
down menu
1. Option to
create
geometry and
mesh

2. For this
3. To add the quad mesh to the grid, simulation,
use the add button and click on the mesh
points (4 points) in the grid (quad) is used
to create
rectangular
4. Click shape parts
OK

For the plates a dimension of 64mm x 2mm is used. The weld filler is 1mm x
mm.

The figure above shows the result after selecting the 4 corner points. The figure
bel;ow shows the result after all geometry is added (weld, table, and second
plate)

Wel Plate
d 2

Plate
1 Table
 4. Creating sets. To help simplify the next steps, it is useful to separate the
geometries into sets.

1. The first
step in
creating sets
is to right click
the model, 2. The second step is to assign a name
select sets, for that set. Write the element name,
new set and press enter and click on the element.
elements

The element sets in this simulation are: plate1, plate2, weld, and table. On the
side menu, we can change the visibility of the sets by checking or unchecking
the box beside the set name.

5. Subdivide. This option will enable us to subdivide the parts (set) into smaller
elements. However, when subdividing we have to keep in mind that the student
version only support ups to 5000 nodes. Subdividing into too many elements will
result in excessive nodes.

1. Click on the subdivide

option under the operations
tab.

2. The amount of sub

elements in x y and z
direction
The amount of
bias

4. Select the
5. Click 3. Click on element, then
OK Elements Right click
 Figure above shows the element after subdividing.

Repeat the steps before for Subdividing the Filler and Table. The Filler and Table are
subdivided with the above parameters. No bias factors for weld filler and table.
 6. Expand. To expand the element into 3D since the length is 200 mm the value
is input into the from/to tab.

4. Click All
existing to select
all the elements
1. Click
Expand
2. Insert the
length of the
expand

3. Click
Expand
Elements
5. Click
OK

After expanding:
 6. Re sub dividing. After expanding, the expanded elements need to be subdivided.

3. Select All existing to expand all

elements
1. Put 10 for the
expand in z-
direction

2. Click
Elements

4. Just press
OK

7. Sweep. This option is to remove stacking nodes. Since only 5000 is allowed for
student edition, sweep will reduce the number of nodes to acceptable amount.

1. Click
sweep
2. Select
All

3. Press
OK
 8. Geometric properties. All geometries in this simulation is solid. The constant
temperature option is checked for all geometry.

1. Click
Geometric

Geometri
2. Select
New
(structural)

c
3. Choose for
Solid

1. Rename
Propertie
s
for each
element

4. Click Add and apply to the

visible nodes, then Right
click

3. Un-tick
other element
except for
Plate1
2. Check the 5. Click
constant OK
temperature
Use the set check box to toggle the visibility of the sets. Apply this step for Plate2,
Filler and Table by tick each of the elements box (step 3.).

Material
Propertie
s
 10. Material properties. To set the material properties of all the geometries. C15
material is used.

1. Click on material and

import button

2. Select the c15

material

3. Press
OK

3. Click this to select All

existing, then Right
click

1. Click this icon to

enter the Material
Properties

2. Click
add
4. Press
OK
 Contact
Propertie
s
 11. Contact properties. First the mesh is determined whether it is rigid or
deformable. All parts are deformable except the table (rigid).

1. Click Contact

2. Click New and

select Meshed
deformable

1. Rename
for each
element

4. Click visible unit

for only Plate1, then
Right click

3. Click

2. un-tick the other

element to add
element only Plate1
5. Click

Repeat these steps for Plate2 and Filler by tick each of the elements box (step 2.).
For Table we chose Meshed (Rigid)
 1. Click New and
Choose Meshed (Rigid)
for Table

3. Click all
visible, then
Right click
2.
Add
2. Tick only for
Table

2. Click
OK

12. Contact table. To determine the relationship between parts.

1. Click New
on contact
bodies 3. Rename
2. Choose Touching
Deformable vs
Deformable

4. Click
OK
 1. Rename

2. Change to
Glued

3. Click
OK

Repeat the steps before for Glued interaction.

1. Click 2. Click
Contact New
tables

3. Choose the
contact interaction
for each of the
contact elements
2

3
1

Repeat these steps for other contact interactions.

This figure shows the complete table of all contact interactions.

Toolbox
(For Weld
Filler and
Weld Path)
 1. Click on the toolbox
tab
2. Click new on Weld
Paths

1. Click Add
nodes

2. Select all the middle nodes

on the top of the weld fillers,
and then right click.
1. Repeat the same steps as
above by selecting the bottom
nodes and the press right click

1. Click New under Weld Fillers

tab

2. Left this box

uncheck

4. Click All Visible then press

right click. Make sure only
fillers element is visible

3. Press
 Initial
Condition
 16. This option is selected to input the condition before the welding process take
place.
2
Change analysis
class to thermal and
structural
1
Click here for
initial
condition.

Surrounding temperature is 20 degree Celsius

2
Enter
initial
temperatu
1
New
thermal

3 Check 4
temperature Check both
top and
5
Add to all bottom
element
Boundary
Condition
 17. This option is used to control the conditions of the welding process.
1. Table is fixed (displacement)
2. Clamping. 1
3. Weld input. Click
4. Face film boundary
condition

Select 2
structural.
Then fixed
displaceme
nt Check all
3 displaceme
nt axis xyz

4 Add nodes
from table

Clamping

2
1
Amount of
Select clamping force
structural. and direction
Then point

3
Click add
then on the
nodes

Weld input parameters.

 Check flux and enter power [Nmm/s]. Since the
unit selected is in mm, the value must be
2 multiplied by 1000.
1
Select 1440 watt = 1440 Nm /s
thermal. Then = 1440 N x 1000mm/s
volume weld
flux = 1.44e6 Nmm /s or 1440000
4
The weld velocity. Select the weld
path and weld filler (made earlier)
3
The Goldak 5
parameters of Add the weld filler
the heat source elements
(in mm)

Face Film

3
1 Input
Select ambient
thermal. temperature
Then face

2
Check

4
Input value for film
coefficient. This value
5 is taken from Simufact
(W/(mm2K))
Emmisivit

Applying face film (Step 1)

Click add then

click all surface. 1
Applying face film (step

Step 2

3
Click all visible

1
Uncheck plate 1
and 2

2
Click
remove
18. Load case

1
Click
2 loadcase
Click new
transient/static

3
Check all

Loadcase
desired load.
4
Apply contact
Determine
table
loadcase time.
Check constant
time step

5 s
Set how many
steps or
increment. Set
the time per
Jobs
 19. Jobs

1
Click on
jobs
2
Select load case

3
Check load

4
Click on check then
run (if no error)

If using subroutine i
like PLOTV

4
Click on

5
Exit number 3004
means simulation
complete with no error

6
Click on open post
file to view result
20. Post processing

Display model plot or i

history plot

i
Select type of display.
Eg: contour bands
Then select results to
display. Eg:
temperature
Results
 i
Time and
increment

i
Type of result

Temperature distribution with contour band display

Temperature distribution with numeric display

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