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
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. Application: E-Vehicle battery frame
 To study the affection of different welding
method to the final distortion.
 Base material: AlMgSi1
 Welding method:
 All MIG
 MIG + FSW
 Welding speed: ~8mm/sec
 Total welding line: 70
 Total welding length: ~30M
9.5cm
CAD Model
Weld line

6. 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

7. E-Vehicle battery frame: Weld sequence design
1
2
3
4
1
2
3
4
Weld plan 1
Weld plan 2
 Different weld sequence could be designed and
simulated easily in Cast-Designer Weld.
 Cast-Designer Weld serves as an easy-to-use
front end to perform welding assembly simulation
for large structure. The physics of welding is fully
treated in the same model.
 The user needs not be familiar with non-linear
FEM simulation, only focus on the process
design.
 Thermal cycle, change the material
status, stresses, plastic strains, thermal
strains, yield stress of the newly formed material
and all other result related to a transient welding
simulation are available.

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. E-Vehicle battery frame: Detail simulation result
Displacement - Z
Displacement
Plastic
strain
Displacement
Residual
stress

10. CAST-DESIGNER | www.c3p-group.com
Cast-Designer Weld Solution WWW.C3P-GROUP.COM
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