Simulation of laser-based welding in the automobile and machine tool sectors
Lasersystemtechnik Bollinger & Ohr (LBO) is a SME specializing in laser-welding technology. The project aims to assess the durability of welded components in automobiles and machine tools by reducing the time needed to assess and optimize a particular weld using a few hours of simulation on an HPC system, thereby avoiding expensive prototypes.
Start date: 01/07/2013
Duration in months: 18
Problem Description
The major advantages of simulations are the savings due to the avoidance of physical prototypes and the faster development cycle. Using simulations, initial results can be available within few hours rather than after days or weeks with prototypes. Models can be modified in order to find optimized welding parameters, such as feed rate, welding penetration depth and laser power. This can contribute dramatically to reducing costs and time. However, there are few, if any, simulation tools to model welding processes.
Goals
Virtual prototyping
Challenges
The challenge of this experiment was therefore to determine and implement a simulation tools for welding on HPC.
Innovation results
Lauer & Weiss (L&W), an expert in the development of software solutions for the automobile and machine tool industry, has developed a simulation of laser-welding processes based on the commercially available ABAQUS package. The accuracy of this methodology has been positively assessed through the physical inspection of welding samples in cooperation with LBO. This confirms that simulated welds accurately model real-world cases and that expensive physical prototypes can be eliminated.
Business impact
BO has conducted four to five expensive welding trials per year. Using Cloud-based-HPC simulations, L&W can generate a significant cost reduction of ~40k EUR per year for these trials. For each new client like LBO, L&W sees a further benefit of €20K to €30K.