Abstract
A general and efficient methodology has been developed to analyze dimensional variations of an assembly, taking into account of weld distortion. Weld distortion is generally probabilistic because of the random nature of welding parameters such as the welding speed, maximum welding temperature, ambient temperature, etc. The methodology is illustrated through a very simple example of two perpendicular plates fillet-welded to each other. Two steps comprise the methodology: establishment of a weld-distortion database, and tolerance analysis using the database. To establish the database, thermo-elasto-plastic finite element analyses are conducted to compute the weld distortion for all combinations of discrete values of major welding parameters. In the second step of tolerance analysis, the weld distortion retrieved from the database is used in addition to the dimensional tolerances of the parts. As a result of such an analysis, sensitivities of the assembly’s dimensional variations to the part tolerances and weld distortion are obtained, which can be help improve the dimensional quality of the assembly.
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