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A manufacturing simulation software


The use of simulation software is today an essential part of the design cycle since it increases company profits by significantly reducing time to market. Virtual prototyping provides engineers with the ability to establish fundamentals of a new project before building prototypes, and allows the economic assessment of the what if scenario.

To fit to this trend, Cenaero decided in 2004 to develop from scratch a new generation manufacturing software, Morfeo (Manufacturing ORiented Finite Element tOol). The ambition is to make of Morfeo the reference in simulation of manufacturing processes for large size components.

Morfeo main fields of application

Morfeo is a computational software tailored for manufacturing process simulation and its impact on the lifespan. Morfeo handles the following manufacturing process to predict the distortion and the residual stress field:

  • Machining
  • Fusion Welding (Laser Beam Welding, Electron Beam Welding, TIG)
  • Solid-state Welding (Friction Stir Welding, Rotary Friction Welding)
  • Additive Manufacturing (Direct Metal Deposition, Laser Metal Deposition, Wired Additive Manufacturing)

Morfeo allows to assess the structural integrity and lifespan within the damage tolerant hypotheses which include:

  • Crack stability assessment considering Linear Elastic Fracture Mechanics (LEFM) and Elastic-Plastic Fracture Mechanics (EPFM)
  • Fatigue Crack Growth (FCG) analysis within LEFM hypothesis

Technical description

The Morfeo foundations are based on both state of the art software development technologies and numerical methods. Written in C++, Morfeo is a modular, object-oriented finite element (FE) application: the Morfeo executable relies on several dedicated libraries for mesh management, mesh adaptation, material behaviour, finite element features, solvers and parallelism.

Parallelism in Morfeo was designed early in the development, providing an efficient and massively parallel simulation tool. The parallelism feature in Morfeo exploits the domain decomposition techniques. Based on MPI (Message-Passing Interface) standard, the parallel version of Morfeo runs on high performance computing (HPC) infrastructure.

Another major advantage of Morfeo consists of the eXtended Finite Element Method (X-FEM), a partition of unity method, thoroughly implemented in the kernel of the code. Combined with Level-Sets and associated efficient evolution algorithms, this method offers many innovative and unique perspectives in material forming processes and fracture mechanics simulations, allowing for minimal remeshing and manual operations.

Morfeo features

To achieve the accurate and fast simulation of manufacturing processes and fracture mechanics problems, the following features are implemented in Morfeo:

  • Temperature formulation for FE heat transfer analysis
  • Displacement formulation for FE structural analysis
  • Velocity/pressure formulation for FE fluid flow analysis
  • Staggered thermo-mechanical coupling
  • Non-linear thermal and mechanical material behavior
  • Multibodies contact treatment
  • Master/Slave detection algorithm
  • Penalty method
  • Friction
  • 2D and 3D mesh adaptation
  • X-FEM enrichment of the finite element approximation with topological or geometrical enrichment
  • Level Sets with associated evolution and/or propagation algorithms
  • J-integral and Stress-intensity factors computation