Diameter vs. Thickness Files

The Diameter Table associates the thickness of flanges with spot weld diameters. The equivalent area is taken to determine the side of the hexa. The table includes flange thickness ranges and corresponding spot weld diameters.

The table below is an example of the values assigned in the Diameter Table. If the main flange thickness is between 1.02 to 1.77, the spot weld diameter will be 4.0.

Flange Thickness Range	Spot Weld Diameter
1.02	4.0
1.78	5.0

The Diameter Table as well as the settings that determine the main flange thickness are available in the Diameter Mapping dialog. To access this dialog, in the Spot panel, set the diameter/use diameter mapping toggle to use diameter mapping and click . You can import or manually define flange thickness ranges and spot weld diameters in the Diameter Table.

Note: If you import a dvst file from HyperMesh v13.0 or earlier, the data will be converted to the new file format.

You can save the information defined in the Diameter Mapping dialog to a diameter mapping.txt file, which can be reused in the future.

1.	Go to the Spot panel.

2.	Set the diameter/use diameter mapping toggle to use diameter mapping.

3.	Click . The Diameter Mapping dialog opens.

4.	Import or manually define flange thickness ranges and spot weld diameters in the Diameter Table.

•	To import predefined values, click File > Open from the menu bar.

•	To manually define values, click to add a row to the table. Default flange thickness ranges and spot weld diameter values will be automatically interpolated. Edit these values accordingly. To remove a range from the table, click .

connector_diameter_mapping_table

5.	For all flanges, define which flange thicknesses to consider when assigning diameter values.

connector_diameter_mapping_consider_main_flange_thickness

•	From the first pull-down menu, select which flanges to consider:

All	Consider all flanges.
Inner	Consider all of the inside flanges.
Outer	Consider the two outside flanges.
Middle	Consider the middle flanges. If there is an odd number of flanges, the very middle flange is considered. If there is an even amount of flanges, the two middle flanges are considered.

•	From the second pull-down menu, select whether to consider the 1st, 2nd, 3rd, or 4th flange the meets the criteria in the third pull-down menu.

•	From the third pull-down menu, select whether to consider the thinnest, thickest, or average (average of all considered flanges, not only the thinnest and thickest) flange.

6.	Optional: If you are connecting 2T, 3T, or 4T thicknesses, you can specify specific flange thicknesses to consider when assigning diameter values to each layer.

connector_diameter_mapping_specific_to

7.	Click Apply.

8.	Optional: To save the diameter mapping table, as well as the settings on how to determine the main flange thickness to a diameter mapping.txt file, click File > Save from the menu bar.

When the connector is realized, only the flanges that meet the criteria defined in the Diameter Mapping dialog will be assigned a diameter value. The flange thickness ranges and spot weld diameter values defined in the Diameter Table will determine the diameter value that is automatically assigned to the spot weld diameter upon realization.

Example

Consider there are five flanges with the following thicknesses:

Flange 1 = 3.0

Flange 2 = 1.5

Flange 3 = 1.0

Flange 4 = 2.0

Flange 5 = 2.5

In the Diameter Table below, four sets of flange thickness ranges and spot weld diameter values have been defined. Below the table, the options have been set to only consider and assign a spot weld diameter to the inner flange with the 2nd thinnest thickness. If there is two layer thicknesses, all of the flanges will be considered, but only the 1st thickest flange will be assigned a spot weld diameter. In this example, there is only one layer.

When the connector is realized, flange 2 will be assigned a spot weld diameter of 4.0.

connector_diameter_mapping_example

Diameter vs. Thickness Files

Diameter vs. Thickness Files

Diameter vs. Thickness Files

All

Inner

Outer

Middle

Example