Process Modelling and Simulation

Engineering simulation and modelling has become widely used by a range of different industry sectors to reduce time and costs during product development and enhance the safe operating life of components by simulating in-service conditions.

Several national and international technology strategies have highlighted simulation as a key enabling technology for everything ranging from defence to manufacturing and engineering analysis.

Simulation and modelling involves the creation of a virtual representation or model of a real-world system, allowing tests to be run virtually to observe its behaviour over time under different conditions.

It is used to test designs and predict outcomes as well as optimising systems without the cost and risk associated with physical prototypes or real-world testing and experimentation. This helps in decision-making by demonstrating how a system will perform in different scenarios.

Simulation and Modelling Applications

Simulation and modelling is used across different industries to test new designs, diagnose problems with existing designs, and evaluate the performance and understand the behaviour of a system.

Industrial examples include assessing energy use and efficiency as well as the durability of a structure, simulating treatment pathways for the medical profession, assessing materials behaviour at different scales, and optimising logistics and supply chains for business.

Core Research Programme (CRP) and Joint Industry Projects (JIP)

Core Research

Each year the TWI Core Research Programme (CRP) addresses challenges on behalf of our Industrial Members as well as developing specific technologies and processes. Each of the projects under the CRP is focussed on engineering, materials or manufacturing technologies.

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Joint Industry Projects

TWI also conducts Joint Industry Projects (JIPs) that bring together groups of Industrial Members to share the cost of research activities in areas of mutual industrial interest, gaining exclusive access to the outcomes. These projects cover a broad range of topics.

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Simulation and Modelling at TWI

Numerical modelling can save significant time and cost at the design stage (Finite Element Analysis), as part of process acquisition, and through to assessing in-service performance (including fatigue modelling). TWI uses welding simulations as virtual tools to help understand how different processing conditions can influence the performance of welded fabrications.

Our modelling capability extends from traditional joining processes, such as arc-welding, to additive manufacture and non-destructive test techniques (e.g. guided-waves), in addition to the prediction of microstructures and residual stress and distortion.

TWI’s expertise lies in our breadth of experience in applying and validating welding and joining simulations, covering most metal alloys (and non-metallics) and industrial applications. By identifying the most suitable modelling approach, we can deliver effective and reliable solutions to meet our customer requirements.

Examples of previous work on manufacturing process simulations include:

Minimising the distortion of a complex, lightweight ship panel containing over 150 different welds by optimising weld sequence
Simulating the electron beam welding of thick section pressure vessels to understand residual stresses and their influence on defect tolerance
Modelling friction stir welding using techniques such as computational fluid dynamics (CFD) or so-called Eulerian techniques
Predicting residual stresses and distortion in additively manufactured (AM) parts made out of Ti-, Al- and Ni-base alloys. TWI’s expertise in AM process simulations is internationally recognised
Analysing the influence of global and local post-weld heat treatment to quantify stress relaxation

TWI’s modelling staff are also actively engaged in the development of codes, standards and industry best practice for weld modelling. This includes participation on and contributions to the UK Nuclear Standard R6 Weld Modelling Guidelines subgroup; British Standard 7910 subgroup on Welding Residual Stress; NAFEMS Manufacturing Process Simulation Working Group; and the ISO/TS 18166 Numerical Welding Simulation technical document.

For more information on how we can assist with your simulation and modelling needs, please email contactus@twi.co.uk

For more information please email:

contactus@twi.co.uk