The unique solution for complex large welding and assembly process, with full chain solution from the material, to process design, to simulation, to production and automatic optimization for welding parameters and assembly sequence

1. CAST-DESIGNER WELD
Efficient design and simulation solution for
complex large welding structures

2. CAST-DESIGNER | www.c3p-group.com
xiuerlee
What is Cast-Designer WELD ?
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CAD
CAE
GA/PSO
DOE
02
Detects
possible
problems
04
Find the best
operation window /
best parameters
01
Existed
design plan 03
Address the
significant affection
factors/parameters
05
Welding
production

3. Challenge for complex large welding structures simulation
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Temperature Distortion
Residual stress Distortion

4. Key technology of Cast-Designer Weld
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Heat source
Distortion
Temperature Distortion

5. Unique Mesh Technology
 Fully automatically mesh generation
 Very strong 3D hexahedron and tetrahedron
mesh capability for complex geometry
 Support GUI mode and batch mesh
mode, fully parametric, easy to re-mesh.
 Special treatment for CAD defects, i.e.
geometry gap, overlay, intersection or
unclose, face lose etc.
 Rich mesh options: local mesh, mark
point, tin region mesh, 2D surface
mesh, shell mesh, advance mesh
smoothing, quality control etc.
 Fully automatic mesh assembly, support
mixture mesh type.
 Bar element as weld line.
CAD
Mesh
Weld line
Detail mesh

6. Welding Heat Source
 Double ellipsoid heat source
 2D Gaussian heat source
 3D Gaussian heat source
 3D uniform heat source
 3D Conical Gaussian heat source
 3D Print heat source
 Combined heat source (Double
ellipsoid + 3D Conical)
 FSW heat source
Double ellipsoid heat source

7. Welding Simulation Model Setup
 Only one windows page to setup the welding
process, boundary condition and control
parameters for heat transfer, flow and stress
simulation
 With rich material data in database, welding
material could be selected from database directly
 Pre-defined template for welding and assembly
process, as well as user can define the process in
free
 All conditions and parameters could be save to
template file for future usage.
 Support automatic optimization directly.
 Welding sequence design and plan interface.

8. Compare different welding process
Displacement
P1
P2 P3
P4
P5
P6 P7
P8
P9
-2
-1
0
1
2
0 50 100
P1 -5
-4
-3
-2
-1
0
1
0 50 100
P2 -5
-4
-3
-2
-1
0
1
0 50 100
P3
-5
-4
-3
-2
-1
0
1
0 50 100
P4 -6
-4
-2
0
2
0 50 100
-4
-3
-2
-1
0
1
0 50 100
P5 P6
-4
-3
-2
-1
0
1
0 50 100
-5
-4
-3
-2
-1
0
1
0 50 100
P7 P8 -3
-2
-1
0
1
0 50 100
P9
 With Cast-Designer Weld, the user can
compare the result of part distortion
and stress for different welding method
or parameters.
 From the contour and curve, the user
can select the best welding process.

9. Detail simulation result
Displacement - Z
Displacement
Average stress
Distortion (front)
Residual stress

10. CAST-DESIGNER | www.c3p-group.com
xiuerlee
Cast-Designer Weld Solution
10
3D Weld DFM
Check
Quotation
Prepare
Process design CAE Analysis
Welding
Production
Welding
Performance
1 3 4 5 6
AI-WELD: Automatic Optimization
SmartWeld CAE Analysis
（FEM + CFD）
Material