Abstract
In this article, a layered shell element-based, elastic finite element method for predicting welding distortion in multi-pass welding is developed. The welding distortion generated in each pass can be predicted by employing layer-by-layer equivalent plastic strains as thermal expansion coefficients and using the heat-affected zone (HAZ) width as the mesh size. The final distortion can be expressed as the sum of the distortions for each pass. This study focuses on extraction of the equivalent plastic strain and HAZ width through 3D thermal elastic plastic analysis (TEPA) for each pass. The input variables extracted from each pass can be converted and added to simulate the final distortion of the multi-pass welding. A 10 mm thick, multi-pass butt-welded joint, subjected to three passes, is simulated via the proposed method. The predicted welding distortion is compared with the 3D TEPA results and the measured experimental data. The outcome indicates that good agreement can be obtained.
Highlights
Welding distortion inevitably occurs in welded structures
We focus on extracting the equivalent strain and heat-affected zone (HAZ) width through 3D thermal elastic plastic analysis (TEPA), along with its application to layered, shell element-based elastic FEM
In the welding distortion analysis method developed by Ha [16], artificial top and bottom temperatures at the nodes, the mesh size at the welding region, and the thermal expansion coefficient are taken as input parameters
Summary
Uneven temperature distribution occurs due to welding, resulting in residual stress and permanent deformation [1,2]. This causes problems such as a decrease in dimensional accuracy and a decrease in productivity. The biggest problem in implementing welding distortion analysis by computer simulation is the fact that welding is a very complex multi-physics phenomenon [4]. Actual welding is a multi-physical phenomenon in which thermal, mechanical, and metallurgical effects occur, and so, the more accurately reflected these are, the longer the calculation time takes exponentially [5,6,7,8,9]. Since the analysis time takes several hours for unit specimens with a welding length of several hundred millimeters, it is practically impossible to apply 3D
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