AnAttAl

Automated local simulation workflow about resistance spot welding for the AnAttAl project (MPA University of Stuttgart)

Simulation Concept

The simulation is organized as a coupled thermo–electro–mechanical workflow.

First, Abaqus is used to build the FE model and generate the .inp file containing geometry, mesh, elements, and material definitions. The .inp is then read by a Fortran-based solver that performs the coupled computation.

Three measured welding signals are used as inputs: force, current, and voltage. The force drives the mechanical part, while current and voltage are used in a resistance submodel to compute the time-dependent electrical resistance. This resistance is iteratively used to update key electrical parameters (e.g., effective conductivity/contact behavior), enabling a realistic representation of resistance spot welding and the resulting temperature and mechanical response.

Repository Structure

This repository primarily demonstrates the structure and implementation of the automated simulation workflow. In the full project environment, the workflow integrates:

Abaqus Scripts

• abaqusMacros.py

Abaqus macro script for geometry generation and preprocessing.

Used to create the FE model and export the .inp file.

.inp Processing Script

• File_Programm2.py

Python script for parsing the generated .inp file and extracting required model data.

Welding Process Data (FAMOS)

• Stromverlauf.txt

• Kraftverlauf.txt

• Potentialverlauf.txt

Measured welding signals (current, force, voltage) used as input for the coupled simulation.

Fortran Simulation Codes

• Testfall_1ms_Dyn5_a_a4.for

Main thermo-electro-mechanical simulation solver.

• odbjoin.for

Post-processing tool for merging restart .odb files.

Compiler Environment

• Compiler 16.0 Update 1 for Intel 64 Visual Studio 2015 environment.lnk

Windows shortcut used to activate the Intel Fortran compiler environment.

However, due to confidentiality and licensing restrictions, project-specific solver implementations, measurement data, and certain subroutines are not included in this public version.

The focus of this repository is therefore on: The workflow architecture; Node dependencies and execution logic; Integration of preprocessing, simulation, and post-processing stages. The provided code illustrates how these components are orchestrated within Pyiron workflow, independent of proprietary project content.

Pyiron workflow

The Pyiron workflow orchestrates these components:

• Geometry modification (Abaqus macro-based)

• Abaqus preprocessing and .inp generation

• Data extraction from .inp files

• Import of welding process data (FAMOS)

• Fortran-based thermo-electro-mechanical simulation

• Post-processing and consolidation of .odb files

The workflow is implemented using Pyiron workflow, enabling structured execution and dependency management across all simulation stages.