spotweld

General Settings

angle

Feature angle of the faces of FE.

Default/Allowed: 25 to 30 degrees

Slide-number

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

Default/Allowed: 1 to 10000

input

Initial directory for the Input file path.

Default/Allowed: C:/temp

output

Initial directory for 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 check on all spot welds, there may be many issues on same welds.

Default/Allowed: ON or OFF

extract-spot-cad

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

Allow searching nearest spot on 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 are calculated after projecting to normal direction.; Default/Allowed: 0.1 to 20.0
checktypes: Allow searching duplicate spot welds on same layer (Same weld plates) or different layer or bot / 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.; 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 has layers more than 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.; 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 angle value and more than gap value 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.; 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 above parameter.; Default/Allowed: 30.0
hole-diameter (f): Search tolerance for finding nearest Bolt holes to avoid finding the issue.; Default/Allowed: 4.0 to 40.0

Creating virtual spot (VS) welds with 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.; 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 tolerance value. Issue is identified if the difference is 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.; 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
do-check: Turn OFF or ON the check; Default/Allowed: ON or OFF
fillet-connelem-tol: Search tolerance for searching nearest fillet edges to the connector.; 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.; 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 issue.

Issues will be ignored if surface offset is not executed and another spotweld exist at 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.; 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.