Abstract
Finite element (FE) method was utilized to analyze the welding temperature field, stress and distortion in a ZS100 motorcycle rear fork. The FE models were simplified due to symmetry of the structure. Simulation results show that temperature distributions, residual stress variation and distortion in the structure are complex and related to welding current. Magnitudes of residual stress occur in HAZ and weld metal for components of side tube-connecting tube and side tube-axle tube. Increasing welding current can result in higher residual stress level and post-welding distortion. Therefore, relative small welding current is preferred for the sake of reduce welding stress and distortion.
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