Manufacturing Solutions

11.0 Tutorials - HyperWeld

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HyperWorks

11.0 Release Notes

Trademark and Registered Trademark Acknowledgments
Listed below are Altair

HyperWorks

applications. Copyright

Altair Engineering Inc., All Rights Reserved for:

HyperMesh

1990-2011; HyperCrash 2001-2011; OptiStruct

1996-2011; RADIOSS

1986-2011; HyperView

1999-2011; HyperView Player

2001-2011; HyperStudy

1999-2011; HyperGraph

1995-2011; MotionView

1993-
2011; MotionSolve

2002-2011; HyperForm

1998-2011; HyperXtrude

1999-2011; Process Manager 2003-2011;

Templex 1990-2011; Data Manager 2005-2011; MediaView 1999-2011; BatchMesher 2003-2011;
TextView 1996-2011; HyperMath 2007-2011; ScriptView 2007-2011; Manufacturing Solutions 2005-2011;
HyperWeld 2009-2011; HyperMold 2009-2011; solidThinking 1993-2011; solidThinking Inspired 2009-2011;
Durability Director 2009-2011; Suspension Director 2009-2011; AcuSolve 1997-2011; and AcuConsole
2006-2011.
In addition to HyperWorkstrademarks noted above, GridWorks, PBS Gridworks, PBS Professional,
PBS and Portable Batch Systemare trademarks of ALTAIR ENGINEERING INC., as is patent #6,859,792. All
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owners.
Manufacturing Solutions 11.0 Tutorials - HyperWeld i Altair Engineering
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Manufacturing Solutions 11.0 Tutorials - HyperWeld
........................................................................................................................................... 1 HyperWeld
........................................................................................................................................... 3
FSW-0010: Introduction to Friction Stir Welding
........................................................................................................................................... 9
FSW-0020: Butt Joint Analysis
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HyperWeld
The following tutorials will give you hands-on experience using the HyperWeld interface.
FSW-0010: Introduction to Friction Stir Welding
FSW-0020: Butt Joint Analysis
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FSW-0010: Introduction to Friction Stir Welding
Manufacturing Solutions includes an interface for friction stir welding simulation. This interface provides all the
tools to create data for friction stir welding and launch the solver. The FSW interface uses the HyperXtrude
solver to obtain the solution, therefore you will find a lot of similarity between the HyperXtrude and FSW
interface. In addition, it is possible to use the FSW interface to create HyperWeld data decks.
Data generated for HyperWeld analysis is organized into two files: GRF and TCL files. The GRF file contains
the mesh, material data, boundary conditions, and other special data. The TCL file contains commands to
set process parameters and control the solver operations. These commands are in TCL language. In order to
make this process of generating data files simple and efficient, the following features are embedded in the
interface.
The HyperMesh Window

HyperMesh main window
There are several main areas in the HyperMesh window:
Title bar The bar across the top of the interface is the Title bar. It contains the version
of HyperMesh that you are running and the name of the file you are working
on.
Graphics area The Graphics area under the title bar is the display area for your model. You
can interact with the model in three-dimensional space, in real time. In
addition to viewing the model, entities can be selected interactively from the
Graphics area.
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Pull down menu Located just under the title bar. Like the pull-down menus in many graphical
user interface applications, these menus "drop down" a list of options when
clicked. Use these options to access different areas of HyperMesh
functionality.
Toolbar Located just under the graphics area, these buttons provide quick access to
commonly-used functions, such as changing display options.
Command Window You can type HyperMesh commands directly into this text box and execute
them instead of using the HyperMesh Graphical User Interface.
Utility Menu This area contains five pages of macros that perform various functions. The
Disp macro page is active and is shaded to signify this. The Disp page
macros control how a model displays in the Graphics area.
The other macro pages available are QA (contains element checking
macros), Mesh (contains macros associated with creating and editing
meshes), User (contains macros you create), and Geom (contains macros
related to working with a models geometry).
The content of the macro menu changes based upon the selected user
profile.
Header bar The Header bar separates the Graphics area from the Panel area. The left
end of the Header bar displays your current location. At this time, you will
see Geometry displayed. The three fields on the right side of the header bar
display the active user profile, current component collector and current load
collector. The latter two fields are blank.
As you work in HyperMesh, any warning or error messages also display in
the Header bar. Warning messages appear in green and error messages
appear in red.
The quit button on the rightmost end of the Header bar ends the HyperMesh
session. When you select quit, if changes have not been saved a save file
information confirmation message appears so you can save your changes
before HyperMesh closes down.
Hint You can hold the left mouse button down on top of a panel to see a
description for it in the Header bar.
Page menu The Page menu allows you to select different sets of functions.
The Geom page contains functions having to do with the creation and editing
of geometry.
The 1D, 2D, and 3D pages contain element creation and editing tools grouped
according to element type.
The Analysis page contains functions to set up the analysis problem and
define the boundary conditions.
The Tool page contains miscellaneous tools and model checking functions.
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The Post page contains post-processing functions.
Panel menu The Panel menu displays for each page the functions available on that page.
You access those functions by clicking on the button corresponding to the
function you wish to use.
Friction Stir Welding User Profile
HyperMesh is designed to accommodate many different FE solvers. As a result, some panels may be too
general for FSW. By selecting the FSW profile, you can work with pre-defined panels that are more specific.
To load the HyperWeld user profile:
1. Launch HyperMesh 10.0.
2. On the Preferences menu, click User Profiles.
3. For Application, select Manufacturing Solutions.
4. Select Friction Stir Welding.
5. Click OK.

Friction Stir Welding Utility Menu
The FSW Utility Menu lists options to import models into HyperMesh, create weld mesh, select and assign
material properties, define and apply boundary conditions, define process conditions, and export data files to
HyperXtrude.
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Buttons in the macro menu fall into two categories:
Shortcuts to native HyperMesh panels
TK popup menus
Import Data
CAD Imports CAD drawing.
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HM Imports an HyperMesh file.
FSW Imports a HyperWeld data deck, including both the GRF and TCL files.
Select Units Allows you to set the units used in modeling the problem.
2D Elems Allows you to control 2d element display.
3D Elems Allows you to control 3d element display.
Loads Allows you to control display of Loads.
Lines Allows you to control display of Lines.
Surfs Allows you to control display of Surfaces.
Material Data
This macro button allows you to select materials from material database
and assign material properties to different components. You can also
view Viscosity/Flow stress graph for a material.
Process Data These macro buttons allow you to define boundary conditions, solution
monitoring points, job control parameters, and model summary.
Boundary Conditions
Inspect/Setup BCs Allows you to view and assign boundary conditions on element faces.
Check Undefined BC
Identifies external faces without loads.
Check Duplicate BC Identifies duplicate loads.
Process Data
Parameters Specifies process control parameters.
Extract Points Defines solution-monitoring points. The HyperXtrude solver prints
detailed solution history at these points.
Model Summary Inspects summary data such as number of elements and loads.
Export Data
FSW Saves an FSW data deck and start the HX solver.
HM Allows you to save the data in HyperMesh format.
Launch Solver Allows you to Launch HX Solver using the current model, using Data
deck or using a restart file.
Return to Friction Stir Welding Tutorials
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FSW-0020: Butt Joint Analysis
In this tutorial, you will analyze a friction stir welding of a butt joint. This example shows you how to set up
the data for HyperXtrude and solve the problem.
All files referenced in this tutorial are located in the HyperWorks installation folder <install
directory>\tutorials\mfs\fsw\FSW_0020. If you do not know the location of the HyperWorks
installation folder on your system, please contact your systems administrator.
To work on this tutorial, it is recommended that you copy this folder to your local hard drive where you store
your HyperXtrude data, for example, C:\Users\HyperWeld\ on a Windows machine. This will enable
you to edit and modify these files without affecting the original data. In addition, it is best to keep the data on
a local disk attached to the machine to improve the I/O performance of the software.
Process
The process for analysis using FSW is as follows:
1. Select the units for the analysis.
2. Create data files for butt weld joint.
3. Mesh the computational domain.
4. Assign material properties and process conditions.
5. Export the data files.
6. Visualize the model in HyperXtrude and inspect material and bcs.
7. Launch HyperXtrude. HyperXtrude can also be started from the command line
8. Post-process the results in HyperXtrude.
Exercise
Step 1: Load the FSW user profile
1. Launch HyperMesh 10.0.
2. From the Preferences menu, click User Profiles.
3. For Application, select Manufacturing Solutions.
4. Select Friction Stir Welding.
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Step 2: Select units
1. On the Utility Menu, click Select Units.
A window displays with the option to select units for length, velocity, temperature, and stress.
2. Select the units to use and click OK.

Step 3: Create the butt weld model
1. On the Utility Menu, click Create Mesh.
The Create Weld J oint window with icons showing available parametric models weld joints display.
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2. Click Butt J oint.
The geometric parameters for the butt weld joint displays. A weld joint is defined by the length, width,
and thickness of the plate geometry. Pin diameter, pin height, shoulder diameter, and shoulder height
are used to define the tool geometry.

3. Review the default data, and click OK to create the mesh and continue to the Process Parameters
window.
4. Click OK to accept the default values.
The process parameters are inputted into this window. The process parameters include: temperature of
plates, rotational speed and translational speed of the tool, friction coefficient at the shoulder contact
surface, convective heat transfer coefficient, and the ambient temperature.
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5. Continue to select material properties.

6. Under System Materials, select H-13 and AA6063.
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7. Click Close.
The mesh generation process completes. The finite element mesh of the weld joint with boundary
conditions displays in the main graphics area.

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8. On the Utility Menu, under Process Data, click Parameters.
The first property page on the parameters widget displays the job control parameters. The second page
contains the process parameters. The third page contains the advanced parameters such as the
nonlinear iteration relaxation parameters. The last page allows you to enter additional run control
commands.
9. Change the J ob/Model Name to FSW_0020 and click Update. Click Close to close the dialog.

Step 4: Summarize the model
1. On the Utility Menu, under Process Data, click Model Summary.
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The inf ormation on the mesh size, type of elements, boundary conditions, and materials displays.
Step 5: Export data files
Next you will save the mesh, material properties, boundary conditions, and process conditions in
HyperXtrude solver data file format.
1. On the Utility Menu, under Export Data, click FSW.
2. Use the browser window to select the directory to store data files.
3. Save the file as fsw_0020.grf.
4. Click Export.
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Step 6: Load the model to HyperXtrude
1. Using a command window, go to the location of your work directory.
2. At the command prompt, type %hx I butt_joint.tcl.
HyperXtrude launches and loads the tcl file.
3. Click View to launch the main viewport where the geometry is displayed.

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Step 7: Inspect materials and process parameters
1. From the Properties menu click Material.

A f orm containing the material properties of aluminum displays.
2. Verify that the material properties are the same as the ones given in butt_joint.grf.
3. Click Plot to view the plot of temperature and strain rate dependent viscosity and flow stress.
4. From the Properties menu, click Process.
A form displaying the reference quantities opens.

Step 8: Open the main viewport
1. From the Windows, menu click Status.
2. Click View to view the main viewport.
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Step 9: Change the background color
1. Click the mesh icon .
2. Select the Graph Opts panel from the Viewport Control Form.
3. Select Background: white.
Step 10: Inspect the boundary edges
1. Click on the BC icon .
2. Click Update to get a list of all the different BCs.
3. Display the boundaries by selecting one at a time and then click the Redraw button.
4. Turn off the mesh and Dismiss the Viewport Control Form.
5. Deselect all the boundaries and Dismiss the Data View Form.
Step 11: Inspect the mesh
1. Leave the boundaries displayed.
2. Select Grid panel from the Viewport Control Form.
3. On the Mesh menu, click Full.
Step 12: Run the analysis
1. Click Solve. This starts the HyperXtrude analysis.
The Ready (displayed in green) button will turn red indicating that the code is busy computing.
2. Observe the run diagnostics on the screen and wait till the Ready button turns green again.
The solution process stops after 25 nonlinear iterations.
Step 13: Post-process the results
1. Click the Load Results icon .
2. Click Set All.
3. Click Apply.
This step loads nodal values of all of the results for post processing. You can also selectively load what
you require to optimize the memory requirements.
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Step 14: Display color plots of the results
1. Click the Isosurfaces icon .
2. Choose Display: flat and click Apply. The pressure solution is shown. The pressure in the solid domain
is equal to zero.
3. Change Color by to Velocity Magnitude.
4. Change Color by to Temperature. Due to the differences in thermal properties of the two materials, the
shapes of the temperature contours in two regions are different.
Step 15: Display particle traces
1. Click the BC icon.
2. Click Select-all to show all BC faces.
3. In the Color bar widget, turn off the color bar.
4. Click the Particle Traces icon .
5. Select the Traces page from the Data View Form.
6. Select Traces Start From: Inflow.
7. Click Launch. The particle traces are displayed
8. Click Erase.
Step 16: Display velocity vectors
1. From the Data View form, select the Vectors page.
2. Set Scale=10 and enable the check box Color by magnitude.
3. Click Apply. The velocity vectors are displayed.
4. Clear the Show check box to turn off the display.
5. Dismiss the Data View Form.
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