Prediction of weld-induced distortion of large structure using equivalent load technique

Mondal, Arpan Kumar; Lohit, Anche; Biswas, Pankaj; Bag, Swarup; Das, Manas

doi:10.1177/0954405416646309

Cited by 11 publications

(5 citation statements)

References 37 publications

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“…The temperature-dependent material properties are represented in Figure 1 and Table 1. 22 The density of the material was kept constant as 7850 kg/m 3 . 23…”

Section: Numerical Modelingmentioning

confidence: 99%

Evaluation of through-thickness residual stresses and microstructure in SA516 Gr. 70 steel welds

Taraphdar

Mahapatra

Pradhan

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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The critical working condition of nuclear power plant equipment necessitates meticulous determination of the welding process and parameters. In this work, some major influential factors of welding were investigated to observe their effects on the through-thickness residual stress distribution in multipass pressure vessel steel welds. In this regard, experiments were conducted to find the characteristics of residual stresses dispersed in SA516 Grade 70 steel welds of different groove geometries with distinct welding conditions. Three-dimensional finite element models of the weldments were developed considering a moving heat source with temperature-dependent material properties to simulate the welding thermal cycles and corresponding residual stress fields. Effects of weld groove geometry, number of weld passes, external constraints, and preheating on the through-thickness residual stress fields were studied. Additional attention was given to the evaluation of the heterogeneous microstructure and microhardness across the weld cross-section associated with their weld thermal history. Finally, the evolution of the through-thickness residual stresses attributed to subsequent weld passes was elaborated.

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“…The temperature-dependent material properties are represented in Figure 1 and Table 1. 22 The density of the material was kept constant as 7850 kg/m 3 . 23…”

Section: Numerical Modelingmentioning

confidence: 99%

Evaluation of through-thickness residual stresses and microstructure in SA516 Gr. 70 steel welds

Taraphdar

Mahapatra

Pradhan

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

show abstract

“…Thus, it has good practical signi cance and development prospects. Since the 1990s, Japanese researchers have introduced the theory of inherent strain in welding simulation studies, which have been widely applied in the marine industry [10][11][12]. Corresponding results have been achieved in butt welding, llet welding, plane segment welding, and surface welding of large complex structures [13][14][15].…”

Section: Introductionmentioning

confidence: 99%

Process optimization-oriented deformation control of large aluminum alloy structures from high-speed EMU

Li,

Liu,

Zhang

et al. 2024

Preprint

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Predicting and controlling the welding deformation of large aluminum alloy structures is crucial to ensure the accuracy during the manufacturing of high-speed electric multiple units (EMUs). On the basis of heat source calibration, the dual ellipsoid heat source model and simplified equation parameters were used for metal-inert gas (MIG) welding, and the simulation of residual stresses obtained from the three numerical simulation methods were compared with the experimental values, and it was determined that the thermoelastic-plasticity method was used as a method to establish a high-precision inherent strain database. Based on this database, the welding deformation of the entire sidewall (23 m, 44 welds) was predicted and compared with the experimental data, and the error of the two results was less than 1 mm, and the simulation model was able to reflect the actual situation. Meanwhile, on the basis of this model, the effects of welding sequence, spot fixing method and number of clamps on welding deformation were investigated separately, and the results showed that: the reasonable welding sequence reduced the maximum deformation by 30.90%; the appropriate spot fixing method reduced the maximum deformation by 12.56%; and the reduction of the number of clamps by 9% could get the same effect as the original scheme, and the reduction of the number of fixtures by 18% could still ensure that the overall deformation was basically unchanged. Thus, process optimization can effectively control welding deformation, providing insights for improving the welding quality of aluminum alloy-based high-speed EMUs structures.

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Section: Introductionmentioning

confidence: 99%

Process optimization–oriented deformation control of large aluminum alloy structures from high-speed EMU

Li,

Liu,

Zhang

et al. 2024

Weld World

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Predicting and controlling the welding deformation of large aluminum alloy structures is crucial to ensure the accuracy during the manufacturing of high-speed electric multiple units (EMUs). On the basis of heat source calibration, the dual ellipsoid heat source model and simpli ed equation parameters were used for metal-inert gas (MIG) welding, and the simulation of residual stresses obtained from the three numerical simulation methods were compared with the experimental values, and it was determined that the thermoelastic-plasticity method was used as a method to establish a high-precision inherent strain database. Based on this database, the welding deformation of the entire sidewall (23 m, 44 welds) was predicted and compared with the experimental data, and the error of the two results was less than 1 mm, and the simulation model was able to re ect the actual situation. Meanwhile, on the basis of this model, the effects of welding sequence, spot xing method and number of clamps on welding deformation were investigated separately, and the results showed that: the reasonable welding sequence reduced the maximum deformation by 30.90%; the appropriate spot xing method reduced the maximum deformation by 12.56%; and the reduction of the number of clamps by 9% could get the same effect as the original scheme, and the reduction of the number of xtures by 18% could still ensure that the overall deformation was basically unchanged. Thus, process optimization can effectively control welding deformation, providing insights for improving the welding quality of aluminum alloy-based high-speed EMUs structures.

show abstract

Prediction of weld-induced distortion of large structure using equivalent load technique

Cited by 11 publications

References 37 publications

Evaluation of through-thickness residual stresses and microstructure in SA516 Gr. 70 steel welds

Evaluation of through-thickness residual stresses and microstructure in SA516 Gr. 70 steel welds

Process optimization-oriented deformation control of large aluminum alloy structures from high-speed EMU

Process optimization–oriented deformation control of large aluminum alloy structures from high-speed EMU

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