Comil Ônibus Reduces Distortion by 75% Using Weld Planner Simulation Software
Simulating the steel welding sequence using Weld Planner software significantly reduced manufacturing cost and time. The simulation results allowed us to control the dimensions of critical parts and avoid rework in our assembly line.
Comil needed to reduce geometrical distortions of a bus door frame induced by welded assembly.
When the traditional trial-and-error method, and consequential mechanical rework, failed to reach the required quality, Comil turned to ESI simulation software Weld Planner to enable them to meet specifications and cut development time and spending.
- In the first phase, ESI developed a benchmark for Comil to demonstrate Weld Planner capabilities and show the correlation
between numerical and test results.
- In the second phase, Comil became familiar with the software through a formal training program and launched their first project and the task of integrating CAE simulations into their welding process development workflow
- The third and most significant phase required full integration of Weld Planner in Comil’s workflow, and consistent use throughout their welding process development.
One particular Comil bus design incorporated a front door with an inner structure made of steel; a configuration intended to be compliant with the ABNT NBR 7008 standard. The different components of the door were to be assembled and welded by Gas Metal Arc Welding (GMAW). Comil’s prototyping department was in charge of developing the welding device and the welding sequence. In order to develop the welding process, the prototyping team had to perform physical tests and use trial-and-error to optimize the
welding device and welding sequence.
- Meeting tolerance requirements of welded assemblies without tedious trial and error on the shop floor
- Improved product quality, with a favorable customer perception
- Drop in development time, rework activities, and costs previously related to multiple physical trials
- A new cost-reducing workflow that integrates simulation early in the design process