spotweld

General Settings

angle

Feature angle of the faces of FE.

Default/Allowed: 25 to 30 degrees

Slide-number

The starting number shown in the top corner of the PowerPoint file.

Default/Allowed: 1 to 10000

input

Initial directory for the Input file path.

Default/Allowed: C:/temp

output

Initial directory for the report output path.

Default/Allowed: C:/temp

action

User action type to be executed.

Check: Only intersection check will be executed, no reports.
Report: Only Reports will be generated from the previous check.
Both: Check and Report generation will be executed in a sequence.

Default/Allowed: Check, Report or Both

mode

Default options for Run type.

interactive: Check executed in the front ground HyperMesh session
background: Check executed in the background HyperMesh sessions. Automatic restart executed. If errors occur, the errors will be displayed in the browser as "Crash" keyword.

Default/Allowed: interactive or background

vip-format

Space or 8-digit separated format.

Default/Allowed: space or 8-digit

resolveconflictingpid

5 digits or 7 digits format correction.

Default/Allowed: ON or OFF

realize-check

Ignores failed spot welds during the check.

Default/Allowed: ON or OFF

allow-multiple-issues

All checks on all spot welds. There may be issues on the same welds.

Default/Allowed: ON or OFF

extract-spot-cad

Converts CAD points/solids to the spot weld file. A copy of the spot weld vip file will be stored in the CAD folder.

Default/Allowed: ON or OFF

extract-spot-cad-option

Converts point/solid entities to spot weld file.

Default/Allowed: points or solids

realize-tolerance (tol)

Allows searching the nearest spot on the same layer or different layer or bot/all duplications.

Default/Allowed: 1.0 to 10.0

Closest

do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF
Tolerance (tol): Distance between two spot welds less than/equal to this tolerance are reported as duplicates. Distance is calculated after projecting to normal direction.
Figure 3.; Default/Allowed: 0.1 to 20.0
checktypes: Allows searching duplicate spot welds on the same layer (same weld plates) or different layers or bots/all duplications.; Default/Allowed: sameStack, DifferentStack or Both

Spot weld found with the search radius of tolerance is identified.

Gap

do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF
min: Minimum gap between Spot location and the weld plates.
Figure 5.; Default/Allowed: 1.0 to 10.0
max: Maximum gap to be considered between Spot location and the weld plates. This value is added to filter some spotwelds which are too far from the model.; Default/Allowed: 10.0 to 100.0

Spot weld between min and max distance from the nearest flange is identified, perpendicular distance is checked.

Single-Layer

do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF

Self-welded spot welds are identified for reference. The link component 1 and link component 2 is same.

Multi-Layer

do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF
threshold: Maximum allowed spot weld layers.; Default/Allowed: 2 to 4

Spot welds that have layers more than the threshold value are identified for reference. It is expected to have a notch to allow Spot gun.

hm-issue

do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF

Spot welds that are far from the sheet metal part by “tolerance” search are identified and part missing issues are directly identified by HyperMesh.

Tol: realize-tolerance (tol)

Parallel-flanges

do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF
angle: Maximum angle between two plates at spot location.
Figure 10.; Default/Allowed: 2.0 to 15.0
max-gap: Maximum physical gap between two plates at Spot location.; Default/Allowed: 1.0 to 5.0

Non-Parallel flanges are identified at Spot weld location. If the angle between two sheet metal parts is more than the angle value and more than the gap value they are identified.

Incorrect-Location

do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF
min-distance (min): Minimum distance allowed from feature-line to the spot location.
Figure 12.; Default/Allowed: 1.0 to 5.0

Issue is identified if the distance between Spot weld and the nearest feature edge is more than the tolerance value. The tolerance refers to Spot gun “radius+gap”.

Few-Connections

do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF
Proximity (a): Search tolerance for realizing spot weld on the flanges, it is global pitch.; Default/Allowed: 1.0 to 5.0 mm
pitch-spacing (b): Average pitch distance for creating spot weld on flange.; Default/Allowed: 15.0 to 30.0
pitch-offset (c): End offset distance on both side of the flange.; Default/Allowed: 5.0 to 8.0
pitch-edge-distance (d): Offset distance from the edge of the flange.; Default/Allowed: 5.0 to 8.0
search tolerance (e): Tolerance for searching Virtua connectors from existing connectors created from the above parameter.; Default/Allowed: 30.0
hole-diameter (f): Search tolerance for finding nearest Bolt holes to avoid finding the issue.
Figure 14.; Default/Allowed: 4.0 to 40.0

Creating virtual spot (VS) welds with the above parameter. For every virtual connector (VC) search nearest existing spot weld (blue) with “search tolerance” value, identify location (yellow), if blue spot weld not found.

Flange-gap

do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF
limit: +/- ratio of shortest gap between flanges at connector to average component thickness value. It is also % of deviation.
Figure 16.; Calculation : abs( D - d ) ≤ limit; Default/Allowed: 0.1 to 0.5 mm

This ratio of flange gap to average thickness of the component is compared with the tolerance value. The issue is identified if the difference is the same or less than the limit value.

Note: No Error will be reported if thickness does not exist or offset is not done.

Intersection

do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF
spot-layers: Maximum number of layers considered for this check.
Figure 18.; Default/Allowed: 2 to 3

Intersection on Spot realized FE data is found here or 2 layer to 3 layer or 3 layer to 4 layer conversion possible welds are identified.

Fillets

Fillet identification angle: Figure 20.
do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF
fillet-connelem-tol: Search tolerance for searching the nearest fillet edges to the connector.
Figure 21.; Default/Allowed: 10.0

If Spot welds location less than the fillet-connelem-tol distance from the nearest feature, line is identified here.

Reflect

do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF
reflect-plane: Reflecting plane for the model which the spot welds are reflected and checked again for realization.
Figure 23.; Default/Allowed: zx
origin: Origin value. (for XY plane, origin is constant Z value); Default/Allowed: 0 to 1000.0

Failed spot welds are reflected at reflect-plane and re-realized, if successful in realization, it is identified as an issue.

Issues will be ignored if surface offset is not executed and another spotweld exists at the reflected location.

surrounding

do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF
spot-layers: Maximum number of layers considered for this check.
Figure 25.; Default/Allowed: 2 to 3

Intersection on Spot realized FE data is found here or 2 layer to 3 layer or 3 layer to 4 layer conversion possible welds are identified.