Improved Accuracy of the Inherent Shrinkage Method for Fast and More Reliable Welding Distortion Calculations

Abstract

This paper describes the implementation of a simple strategy adopted for the inherent shrinkage method (ISM) to predict welding-induced distortion. This strategy not only makes it possible for the ISM to reach accuracy levels similar to the detailed transient analysis method (considered the most reliable technique for calculating welding distortion) but also significantly reduces the time required for these types of calculations. This strategy is based on the sequential activation of welding blocks to account for welding direction and transient movement of the heat source. As a result, a significant improvement in distortion prediction is achieved. This is demonstrated by experimentally measuring and numerically analyzing distortions in two case studies: a vane segment subassembly of an aero-engine, represented with 3D-solid elements, and a car body component, represented with 3D-shell elements. The proposed strategy proves to be a good alternative for quickly estimating the correct behaviors of large welded components and may have important practical applications in the manufacturing industry.