Available Modules

Morfeo AM: Predicts distortions and residual stresses in additive manufacturing (AM); more specifically, Morfeo AM simulates powder bed fusion processes. Two different kinds of simulations are available:

1.) The classical inherent strain method: This is a linear elastic or elasto-plastic analysis, with just one time step per macro-layer. As such, it’s very computationally efficient. The inherent strain could be defined as a constant value for the whole part or as a function of predefined multiple geometric fields. In addition, it’s also possible to define the local orientation of the inherent strain tensor.

2.) A transient thermo-mechanical simulation: This kind of simulation is a repeated sequence of layer activation, heating, and cooling that yields a high-fidelity prediction of distortion and residual stress in powder bed fusion processes.

Morfeo Crack: Morfeo Crack can perform fully automated three-dimensional fatigue crack propagation in complex assemblies with the Xtended Finite Element Method (XFEM). Cracks are easily introduced in complex models via level-set functions. Accurate stress intensity factors are computed and used to assess parts’ structural integrity. Adequate level-set update functions and propagation laws are then used to propagate cracks in the mesh, with automatic handling of the topological changes. Few manual interventions are needed with Morfeo Crack, which helps engineers make crucial decisions during design phases or during investigations of critical in-service failures. Coupled with all of Morfeo’s other features, this module also plays a key role in the analysis of manufacturing defects.

Morfeo Machining: An original algorithmic strategy makes Morfeo Machining particularly efficient for the simulation of multi-pass machining simulations. Relaxation of stresses generated during upstream processes is often the most critical source of distortion during the machining process. To predict them, it’s crucial to take the whole sequence of passes into account. Therefore, the level-set (signed distance) technique is used to represent each path so that the workpiece and the different cutting surfaces can be meshed separately. This is better than the classical finite element approach, which would require heavy remeshing operations after each machining step. This method guarantees that cutting paths are defined in an initial undeformed configuration while a deformed workpiece is considered for the next machining pass.

Morfeo Welding: Morfeo Welding proposes a transient numerical model for a variety of welding processes. The modeling of the thermo-mechanical problem allows users to predict the level of residual stresses and distortions at the end of the process. Morfeo Welding optimizes the welding process by modifying the clamping system and/or the welding sequence to improve designs without having to perform expensive experimental works. Welding trajectories can be defined directly from CAD geometry, allowing easy definition of complex and multiple welding paths.

Morfeo Welding also offers the modeling of the Friction Stir Welding (FSW) process. A local thermo-fluid finite element model is available to predict temperature cycles and strain-rates around a FSW tool. Steady-state and transient thermo-fluid models are available, allowing users to easily model the flow and temperature fields around tools with complex geometry. The primary advantage of this model is the reduction of the need for heat input measurements from FSW experiments. The model can also be used to simulate the Friction Stir Spot Welding (FSSW) process.

The results from the thermo-fluid model may be used as input for various additional studies and analyses. For example, the temperature distribution history may be applied to a metallurgy model to determine the hardness variations across the weld, or the viscous dissipation may be used as a heat source in a global thermo-mechanical simulation to predict the residual stresses in the welded component.

Products Not Currently Available Through the APA

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