DFLUX
Inherent strain method in Metal Additive Manufacturing simulation (using subroutines and Python scripting in Abaqus)
This tutorial package focuses on the Inherent Strain method in Abaqus, an efficient numerical approach to simulate Laser Powder Bed Fusion (LPBF) in metal additive manufacturing.
It addresses the high computational cost of detailed thermo-mechanical LPBF simulations by utilizing an agglomeration approach to transfer inherent strain from micro to macro-scale models. Through theoretical explanations and practical workshops, users will learn to implement the ISM method, including Dflux and USDFLD subroutine coding and Python scripting, for improved LPBF process simulation control. This product does not utilize AM plugins, making it ideal for users who prioritize transparency in calculation methods and flexibility in variable modification for similar models.
Laser Assisted Machining (LAM): Modeling and Simulation in Abaqus/CAE
In this tutorial, a comprehensive discussion on modeling and simulation of laser assisted machining is presented. It includes building FEM-based models of machining, laser heating, and laser-assisted machining models in Abaqus/CAE. The finite element method (FEM) simulation is based on the coupled thermo-mechanical behavior. The package walks learners through building models that simulate the impact of laser heating on the workpiece. Detailed lessons cover constructing basic machining and laser heating models, setting boundary conditions like cutting speed and laser power, and writing subroutines such as DFLUX and VDFLUX to simulate laser heat sources. Additionally, learners will perform analyses to study temperature distribution, and stress-strain behavior. Through parametric analysis and comprehensive result evaluation, learners will gain a deep understanding of temperature distribution, stress behavior, and how laser heating can improve the machining process.
Laser Forming Process Tutorial in Abaqus
The laser forming process is performed by applying thermal stresses to the workpiece surface by heating the surface with a laser beam. These internal stresses induce plastic strains in the part resulting in local elastic-plastic deformation (Laser-induced plastic deformation). In this laser forming simulation tutorial the DFLUX subroutine is used to apply heat flux (Gaussian heat distribution) dependent on location and time in finite element simulation. For example, the linear heating processes of laser forming and welding (with a slight simplification) can be simulated by this subroutine. In the linear heating process, by applying heat flux to the surface of a sheet, a thermal gradient is created in its thickness. This thermal gradient causes permanent deformation of the sheet. To simulate the laser forming process, it is necessary to apply a time and location-dependent heat flux to the sheet. In this type of loading, a heat flux is applied on the plate, which is defined using the DFLUX subroutine, including the laser power, movement speed, beam diameter, absorption coefficient, and laser movement path according to the designed experiments (Laser forming process parameters). To verify this Abaqus laser forming simulation, the simulation results and experimental results of sheet deformation (U) are compared. The displacement of the sheet in the simulation is in good agreement with the experimental results.
Arc welding simulation in Abaqus
Arc welding is a fusion process that involves joining metals by applying intense heat, causing them to melt and mix. The resulting metallurgical bond provides strength and integrity to the welded joint. Arc welding is widely used in various industries for fabricating structures and components. Arc welding simulation in Abaqus is essential for optimizing the welding process and ensuring high-quality welds. It allows engineers to predict and analyze factors such as temperature distribution, residual stresses, distortion, and microstructure evolution during welding. By accurately simulating the welding process, parameters like welding speed, heat input, and electrode positioning can be optimized to achieve desired weld characteristics and minimize defects.
DFLUX Subroutine (VDFLUX Subroutine) in ABAQUS
DFLUX subroutine (VDFLUX Subroutine) is used for thermal loading in various body flux and surface flux states in heat transfer and temperature displacement solvers when flux load is a function of time, place, or other parameters. In this package, you will learn “when do you need to use this subroutine?”, “how to use the DFLUX subroutine”, “what is the difference between DFLUX & VDFLUX?”, “how to convert DFLUX to VDFLUX and vice versa?”, and “How to use it in an example?”. Three workshops are presented so you can learn all these stuff in action: Simulation of welding between two plate with DFLUX subroutine, Simulation of Arc welding between two tube with DFLUX, and Simulation of different types of functional heat flux(Body-surface-Element) in plate with Johnson-cook plasticity with VDFLUX subroutine(Thermomechanical Analysis).
Welding Simulation in ABAQUS
This training package fully covers the various possible methods for welding simulation. First, an introduction to welding and two basic categories of welding, fusion and non-fusion welding. Next, the theories and the elements used to simulate the welding will be explained. These theories are Lagrangian, Eulerian, ALE, and SPH. After that, you will learn how to apply these theories with different methods, such as the death and birth of an element, DFLUX subroutine, etc. Next, we have discussed the simulation of two-pass gas metal arc welding Processes in Abaqus, in a manner that can be extended to multi-pass and other types of welding. This heat flux created by the electric arc is transferred to the welded parts and leads to a significant increase in temperature. To do so, we will use Goldak's Double Ellipsoid Heat Source Model with the DFLUX subroutine (Considering the death and birth of elements). Finally, you will learn how to simulate welding with the help of six workshops: Friction Stir Welding (FSW) simulation with the Eulerian element, Explosive welding simulation, simulation of FSW with the SPH method, Butt welding with death and birth of an element method, Simulation of Arc welding between two tubes with DFLUX subroutine (Thermomechanical Analysis), and simulation of Two-Pass Arc Welding (Including the Birth and Death of Elements) and Its Extension to Other Welding Types.
