Definition by the extended master connection file (XMCF)

For the fatigue analysis of seam welds, the local geometry plays a vital role. Therefore it is essential that a robust analysis process can ensure the usage of the best possible models for the notch stress method at each calculation point in all the seam welds. [4]

Typical parameters are depicted in the following figure of a Y-joint. The diagram on the left side shows typical sheet parameters for sheet thickness (t), sheet angle (α), and gap (c) between the sheets. The diagram on the right shows typical weld parameters: throat thickness (a), throat angle (β), and penetration distance (d). [8]

Parameters for a Y-Joint

All these parameters have a definite influence on the fatigue life and should be known for a fatigue analysis. [4]

One way to ensure a safe process is to include the fatigue-relevant parameters in the seam weld definition files. These files should be created with the assembly definition. This way the position and type of welds are known. The German car manufacturers are currently working on the definition of such a standard format, called the extended master connection file or XMCF. [8] The XMCF file lets you store weld parameters in a process-safe way.

Process Using a Standardized Connection Format for Including Detailed Fatigue Information

There are three different entry points in the seam weld definition process to enter and modify the seam weld parameters and to create and modify the XMCF file: the CAD tool, the meshing tool, and the fatigue tool (as shown in the following figure). Currently, implementations in Specialist Durability exist only for the meshing and fatigue tools.

If the definition is not done until meshing, the fatigue tool needs to able to automatically detect welds by their topological connection in the mesh. The automatic weld detection described in [1] has been enhanced to support all the parameters, shown as examples in the figure Parameters for a Y-Joint and defined in [8]. (See also Automatic seam weld recognition.)

Process in the Fatigue Code: First Automatic Groups of the Connected Sheets Are Created, Then the Weld Line Is Detected, for the Analysis the Local Weld Parameters Are Attached

The sheet parameters are detected from the mesh. For the weld parameters, default values are used that may then be altered in the tool and saved in the XMCF format (as shown in the preceding figure). Because the weld parameters are saved in the XMCF definition file and can be automatically used for the fatigue analysis, the XMCF file allows for very easy subsequent analyses with different variants of the calculated component. [4]

Learn more

Structural stress methods

Notch stress methods

Automatic seam weld recognition

Seam weld fatigue life analysis bibliography

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Definition by the extended master connection file (XMCF), Simcenter 3D 2021.1 Series

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