3-D Finite Element Modeling of the Welding Process Using Element Birth and Element Movement Techniques

Abstract

The modeling and simulation of the welding process has been of main concern for different fields of applications. Most of the modeling of such a problem has been mainly in 2-D forms that may also include many sorts of approximation and assumptions. This is due to limitations in the computational facilities as the analysis of 3-D problems consumes a lot of time. With the evolution of new finite element tools and fast computer systems, the analysis of such problems is becoming in hand. In this research, a simulation of the welding process with and without metal deposition is developed. A new technique for metal deposition using element movement is introduced. It helps in performing full 3-D analysis in a shorter time than other previously developed techniques such as the element birth.

Developing a realistic FE analysis method for the welding of a NET single-bead-on-plate test specimen

“…response due to welding is believed to originate in early 1970 [1]. From then on, it has been increasingly applied by researchers as a way to make predictions of welding induced residual stresses and strain [2][3][4][5][6][7].…”

Influence of tacking sequence on residual stress and distortion of single sided fillet submerged arc welded joint

“…Kinematic work hardening was assumed in the analysis. This is a common material model used in the welding analysis together with von-Misses yield criterion and associated flow rules Wang et al, 2011;Lindgren, 2001;Fanous et al, 2003).…”

Three-dimensional Heat Transfer Analysis of Two Wire Tandem Submerged Arc Welding

“…[7][8][9][10][11][12][13] In fusion welding processes involving electrode deposition, only a fraction of the heat is transferred from the electric arc to the weld pool that also receives superheated metal drops from the consumable electrode. 18) Tekriwal et al 7) simulated the transient temperature distribution in gas metal arc welding (GMAW).…”

“…However, the computed results were sensitive to the assumed superheated temperature of the molten electrode droplets. Fanous et al 10) and Mahapatra et al 11) used element deactivation and activation technique, available in commercial finite element (FE) software, to simulate the deposition of the electrode metal. Mandal et al 12) considered two independent volumetric heat sources, superimposed on each other, to simulate heat input during the peak and base current pulses for typical pulsed GMAW process.…”