Welding simulation of complex structures – possibilities and limits

doi:10.1007/s11706-011-0136-2

Front Mater Sci

2011, Vol. 5

Issue (2) : 196-202 https://doi.org/10.1007/s11706-011-0136-2

RESEARCH ARTICLE

Welding simulation of complex structures – possibilities and limits

M. URNER, K. DILGER(

)

Institute of Joining and Welding, Technical University of Braunschweig, Langer Kamp 8, D-38106 Braunschweig, Germany

Download: PDF(636 KB) HTML
Export: BibTeX | EndNote | Reference Manager | ProCite | RefWorks

Abstract

The possibilities of predicting welding distortions are extensive. The boundary conditions used in industrial production play an important role in choosing the right strategy. Not only the right abstraction of the welding process is essential for correct and useful results, the clamping conditions and pre-tack welding are also very important. This article reviews experiments and FEM calculations of welded complex structures of industrial relevance. The examined structure comes from a railway vehicle and contains u-profiles with a sheet thickness of 4 mm. The review starts with the explanation of the researched structure and shows different welding situations, like unclamped and clamped manufacturing. Then the FE model with several weld seams is explained and the used boundary conditions are shown. Finally, the measured and calculated distortions are compared and discussed.

Keywords welding simulation FEM distortion boundary condition clamping

Corresponding Author(s): DILGER K.,Email:k.dilger@tu-bs.de

Issue Date: 05 June 2011

Cite this article:

M. URNER,K. DILGER. Welding simulation of complex structures – possibilities and limits[J]. Front Mater Sci, 2011, 5(2): 196-202.

URL:

https://academic.hep.com.cn/foms/EN/10.1007/s11706-011-0136-2
https://academic.hep.com.cn/foms/EN/Y2011/V5/I2/196

Fig.1 Structural node with one weld seam, CAD-model.

Fig.2 Experimental setup.

Fig.3 Position of the thermocouples along the weld line and schematic experimental setup for distortion measurement.

Fig.4 Pre-tack-welding and weld seam.

Fig.5 Welding device.

Fig.6 Position of measurement.

Fig.7 FE-mesh: weld seams one to four.

Fig.8 Experimentally obtained and calculated time-dependent temperature transverse to the weld.

Fig.9 Comparison of fusion lines in experiment and calculation and global temperature field

Fig.10 Measured and calculated distortions, schematic pre-connected nodes.

Fig.11 Distortion of the structural node with four weld seams.

Fig.12 Comparison of the final distortion.

1	Radaj D. Eigenspannungen und Verzug beim Schweissen: Rechen- und Messverfahren. Düsseldorf: Verlag für Schweiüen und Verwandte Verfahren DVS-Verlag GmbH, 2002, 390S (in German)
2	Josserand E, Jullien J F, Nelias D, Numerical simulation of welding-induced distortions taking into account industrial clamping conditions. In: The 8th International Seminar - Numerical Analysis of Weldability, Graz, Austria, September, 25–27 , 2006
3	Radaj D. Heat Effects of Welding: Temperature Field, Residual Stress, Distortion. Springer Verlag, 1992
4	Goldak J, Chakravarti A, Bibby M. A new finite element model for welding heat sources. Metallurgical and Materials Transactions B, 1984, 15(2): 299–305

[1]	Yan-Hao DONG, Chang-An WANG, Liang-Fa HU, Jun ZHOU. Numerical calculations of effective thermal conductivity of porous ceramics by image-based finite element method[J]. Front Mater Sci, 2012, 6(1): 79-86.
[2]	Yan-Hong WEI, Xiao-Hong ZHAN, Zhi-Bo DONG. Development and application of software packages in welding engineering[J]. Front Mater Sci, 2011, 5(2): 160-167.
[3]	Dieter SIEGELE. Welding mechanics for advanced component safety assessment[J]. Front Mater Sci, 2011, 5(2): 224-235.
[4]	Vesselin MICHAILOV, Nikolay DOYNOV, Christoph STAPELFELD, Ralf OSSENBRINK. Hybrid model for prediction of welding distortions in large structures[J]. Front Mater Sci, 2011, 5(2): 209-215.
[5]	C. HEINZE, C. SCHWENK, M. RETHMEIER, J. CARON. Numerical sensitivity analysis of welding-induced residual stress depending on variations in continuous cooling transformation behavior[J]. Front Mater Sci, 2011, 5(2): 168-178.
[6]	De-An DENG, . Theoretical prediction of welding distortion in large and complex structures[J]. Front. Mater. Sci., 2010, 4(2): 202-209.
[7]	Xue-qiu ZHANG, Jian-guo YANG, Xue-song LIU, Xu-hui CHEN, Hong-yuan FANG, Shen QU. Numerical simulation of weld tab length influence on welding residual stress and distortion of aero-engine disk[J]. Front Mater Sci Chin, 2009, 3(3): 306-309.
[8]	Jun LI, Jian-guo YANG, Hai-long LI, De-jun YAN, Hong-yuan FANG. Numerical simulation on bucking distortion of aluminum alloy thin-plate weldment[J]. Front Mater Sci Chin, 2009, 3(1): 84-88.
[9]	Hong-yuan FANG, Xue-qiu ZHANG, Jian-guo YANG, Xue-song LIU, Shen QU. Discussion and calculation on welding residual longitudinal stress and plastic strain by finite element method[J]. Front Mater Sci Chin, 2009, 3(1): 75-77.
[10]	De-jun YAN, Xue-song LIU, Huan-yu XU, Jian-guo YANG, Hong-yuan FANG, Jing-yang LU. Welding distortion control of automobile engine stator by finite element method[J]. Front Mater Sci Chin, 2009, 3(1): 71-74.

Viewed

Full text

Abstract

Cited

Shared

Discussed