Finite Element Analysis and In-Situ Measurement of Out-of-Plane Distortion in Thin Plate TIG Welding (original) (raw)
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Determination of Distortion Developed During TIG welding of low carbon steel plate
2014
TIG welding is widely used in modern manufacturing industries. In almost all kinds of metals, TIG welding produces high quality welds. Determination of distortions developed during welding is one of the major goals of welding simulation.Predictions of distortions are necessary to maintain the design accuracy of critically welded components in the design stage itself rather than doing corrective measures after welding. The purpose of present work is to predict the distortion developed during TIG welding of low carbon steel plate. In this study, 3-D FE model is developed to analyze the distortion during TIG Welding of steel plate. In numerical analysis thermal and structural analysis were carried out sequentially. The thermal loads are the main input of structural analysis. For the analysis the effect of distortion in different plates were calculated and compared to get the plane of maximum distortion. An experiment was conducted to measure the distortion or deformation in a welded pl...
Welding in the World, 2013
Fusion welding processes are widely used to assemble large thin plate structures such as ships, automobiles, and passenger trains because of their high productivity. However, welding-induced distortion often inevitably occurs during the assembly process. Welding distortion not only reduces the fabrication accuracy of a welded structure but also decreases productivity due to correction works. If welding distortion can be predicted using a practical method beforehand, the prediction will be helpful for taking appropriate measures to control the dimensional accuracy. In this study, an elastic finite element method to predict the distortion accumulated in large and complex structures during the welding assembly process from cutting through straightening is developed based on inherent strain theory and interface element.
This paper presents an investigation of welding sequence based on the effect of distortion induced by gas metal arc welding (GMAW) process. The selected lower arm parts from national car parts manufacturer will be simulated using Virtual Manufacturing and verified through an experiment by means of a real parts production from industry. Distortion happens due to the uneven rate of expansion and contraction during the welding process. Engineers need to prevent or reduce welding distortion since it could be less cost-efficient to be corrected. Distortions affect the accuracy as well as weld quality. In industry, they use a lot of clamps to prevent distortions. However, with proper welding sequence and lower predicted distortion, lesser clamping setup needed to support the welded part. In this study, the distortion of the lower arm due to changing in welding path/sequence will be analyzed. Simufact. welding 4.0 software will be used to simulate the welding process and the result will be verified by an experimental investigation. . Goldak’s double ellipsoidal model was selected to model the heat source of the GMAW process. The specification of lower arm used is obtained from collaboration with one of the biggest stamping company in the industry. The result from the simulation show that welding sequence does contribute to the distortion of welding process. The sequence can be manipulated to get a better welded product which has lower internal stress due to clamping. Simulation is reliable in predicting welding outcome; however, human expertise is still needed to set up proper simulation. Keyword: welding, distortion, welding sequence, lower arm,welding simulation
Study on the Structure Deformation in the Process of Gas Metal Arc Welding (GMAW)
American Journal of Mechanical Engineering, 2014
This paper investigates the welding deformation via simulation and experiments. The structure of a combined joint geometry was modeled and simulated using Simufact welding software based on the thermo elasticplastic approach. To verify the simulation results, a series of experiments was conducted with three different welding sequences using automated welding process, low carbon steel AISI 1005 as the parent metal, and digital gas metal arc welding (GMAW) power source with premixed shielding gas and the one-sided clamping technique. Based on the results, it was established that the thermo elastic-plastic 3D FEM analysis shows good agreement with experimental results, and the welding sequence "from inside to outside" induced less distortion compared with "from outside to inside". By claiming one plate, the deformation almost locates at the free plate.
Finite element (FE) simulation of welding processes enables the prediction of component distortions which significantly reduces the need for physical trials. This facilitates reduction in lead time and costs associated with process planning. In this paper, FE modelling of tungsten inert gas welding is performed using SYSWELD for a butt joint between 2 mm thick stainless steel 304 (SS304) sheets. A three-dimensional double ellipsoid (Goldak) heat source is used to model the heat flow during welding. The heat source definition as validated against an experimentally obtained grain structure (macrograph) and thermal history. The isotropic hardening material behaviour model is used in the mechanical analysis and the annealing is considered at 1300 uC. FE-predicted distortion for an unclamped situation is compared with an experimental trial. The FE-predicted fusion zone, thermal histories, and residual distortion are found to be in reasonably good agreement with experimental results. The validated FE methodology is further used to perform a parametric study on the effect of natural and forced cooling, clamp release times, and welding sequence on distortion.
IJREAM Publishing House, 2020
It is a well-known fact that fusion welding is being extensively used in a wide spectrum of fabrication industries. In spite of its being a versatile joining process of materials of any thickness, it suffers from some serious setbacks which impair the life of weldments in service. Of utmost concern are the evolution of inevitable residual stresses and distortion in weldments which are the direct result of complex non-uniform thermal cycles experienced during fusion welding. Over the past few decades, finite element method has gained ground as a well-established method to numerically analyze welding related problems. Numerical simulation based on finite element modeling is used to study the influence of welding sequences on the distribution of residual stress and distortion generated when welding a flat-bar stiffener to a steel plate. The simulation consists of sequentially coupled thermal and structural analyses. In Transient thermal analysis, time-dependent temperature distribution is determined. Temperatures from thermal analysis are applied as loads in a structural analysis yielding the three-dimensional residual stress and distortion fields. The effect of four welding sequences on the magnitude of residual stress and distortion in the plate is investigated.
Modeling and Analysis of Distortion in Metal-Inert-Gas Arc Welded Automotive Component
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This paper presents the simulation of Metal-Inert-Gas (MIG) arc welded part distortion and its correlation with test for an automotive engine cradle. A Finite Element Analysis (FEA)-based method is developed to predict the welding distortion. The developed technique has elasticplastic constitutive material model with temperature-dependent material properties. The inherent shrinkage of weld and two weld sequences are simulated. In addition to distortion, residual stress and plastic strain distributions are obtained from the analysis. The heat sink effect is also analyzed using transient thermal-mechanical analysis. The predicted welding distortion is in reasonable accuracy as it correlated with test data.
EFFECT OF HEAT INPUT AND SPEED OF WELDING ON DISTORTION IN MIG WELDING
The objective of this research is to simulate the complex arc welding process by using the finite element method(ANSYS)[]. After the model is built and verified, the main objective of the research is to study the effects of varying the welding process parameters on the thermomechanical responses. In addition to that, the aim of this research is also to find a relationship between welding parameters and thermo-elasto-plastic responses. In this research paper, the responses of single pass corner-joint of arc welding are evaluated through the finite element software (ANSYS). The study of this research paper covers only the effects of varying heat input, welding speed on the thermo mechanical responses of the weldment after cooling down to room temperature.
Materials
This article presents the results of a study on the distribution of weld distortion in thin-walled components made of 17-4 PH steel, resulting from TIG (Tungsten Inert Gas) welding. Both manual and automatic welding processes were examined. Physical simulation of the automated welding process was conducted on a custom-built welding fixture. Analysis of weld distortion in thin-walled components made of 17-4 PH steel was based on the results of measurements of transverse shrinkage and displacement angle values. These measurements were taken on thin-walled parts before and after the welding process using a coordinate measuring machine (CMM). To determine the effect of manual and automated welding processes on the microstructure of the welded joint area, metallographic tests and hardness measurements were performed. The microstructure was analyzed using a scanning electron microscope (SEM). An analysis of the chemical composition of selected welded joint zones was also conducted. These ...
Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2011
Simulation and experiments show that the fixture clamping force has a significant influence on the structural integrity of a welded workpiece. This understanding is of great importance for the manufacture of aerospace components with tight tolerances in the specifications. The focus in the present study is on the temperature history during welding and residual deformation; its main contribution is a demonstrator designed for evaluation of the influence of fixture clamping forces and validation of the simulation results. The demonstrator concerns a simplified situation considering gas tungsten arc welding of a nickel-based metal plate fixed by a specially designed fixture, where one side of the plate was clamped with different levels of force. The temperature history was measured during the weld sequence and deformation measurements were performed after cooling and release of the workpiece from the fixture. The results from simulation and experimentation showed good agreement. The proposed strategy is industrially competitive and has shown that the looser the fixture clamps, the smaller the residual deformation. Furthermore, the study provides a knowledge base for selection of active fixture concepts in that the fixture clamping force can be determined in advance and possibly also be subject to force control.