Introduction
Introduction
Introduction
Typical use cases of virtua RFW
Simulation of rotary friction welding with continuous drive, inertia friction welding and linear friction welding
The process parameters in virtua RFW are exactly the same as in the friction welding machine in the laboratory or in production. Forces and speeds can be specified for the individual process phases and corresponding switches can be defined as normed in DIN EN ISO 15620 or DVS 2909 1-5, respectively.
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Reverse simulation based on machine measurement data
Besides the definition above, it is possible to import the machine data from several machine manufacturers in virtua RFW to include all machine characteristics with greatest detail. The software supports data interface to the file formats of most popular machine brands, such as KUKA, H&W, Raiser, etc.
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Reverse simulation based on machine measurement data (loading of process curves)
Estimation of residual stress fields
Friction welding poses a particularly high risk for residual stresses, as friction welding involves high process forces and the heat distribution is very inhomogeneous. virtua RFW allows to estimate these stresses in a subsequent simulation step of the process simulation.
Estimation of residual stress fields
Machining-off the weld flash
After the welding process, the weld flash might be removed within the machine. This can also be done in virtua RFW in order to better evaluate the effects of flash removal on the local temperature fields.
Definition of flash removal zone, as X-Y coordinate area in machine coordinate system
Hybrid material connections (aluminum-steel, aluminum-copper, ceramic-molybdenum, etc.)
Mixed bonds can be very well analyzed in virtua RFW. In particular residual stress fields, and asymmetric flash formation are very well studied by the process simulation.
Aluminum-Steel friction weld of a gear wheel and aluminum disc.
Simulation of clamping devices and their heat dissipation from the process
The closer the clamping devices are to the friction weld, the greater their influence on the process. virtua RFW helps to evaluate the heat flow within the parts as well as within the clamping devices.
Energy absorbed by the two clamps of both parts (red) and the clamps (blue).
Inductive/conductive heat source and temperature control during welding
A Goldak heat source can also be introduced to simulate hybrid processes that involve inductive/conductive heating in virtua RFW.
