Predicting residual stresses and distortion during multisequence welding of large size structures using FEM

• Published in: International journal of advanced manufacturing technology 2014-07, Vol.73 (1-4), p.409-419
• Main Authors: Keivani, R., Jahazi, M., Pham, T., Khodabandeh, A. R., Afshar, M. R.
• Format: Article
• Language: English
• Subjects: Arc heating; Arc welding; CAE) and Design; Computer simulation; Computer-Aided Engineering (CAD; Distortion; Engineering; Finite element method; Industrial and Production Engineering; Mechanical Engineering; Media Management; Original Article; Plates (structural members); Residual stress; Structural steels; Tee joints; Thermomechanical analysis; Three dimensional analysis; Three dimensional models
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-014-5833-4

A three-dimensional thermomechanical finite element (FE) analysis is carried out to model and predict the influence of welding sequence on the generation of distortions and residual stresses in large size T-joints. To simulate industrial welding conditions, the influence of nine welding sequences on the magnitude of distortion in both the plate and the stiffener was investigated. The addition of new material during welding was simulated using an element “birth and death” technique, while the moving welding arc was considered as a volumetric heat source with a double ellipsoidal distribution. The investigated material is a structural steel used for fabrication of large size structures in the hydroelectric industry. To calibrate the model and validate the simulation results, welding-induced distortion for one sequence was initially modeled and the results were compared with experimental measurements. The optimum welding sequences for the base plate and the reinforcement plate were determined. The results indicated also that the predicted distortions obtained from three-dimensional FE analysis are in reasonable agreement with experimental measurements.