Prediction of Residual Stresses and Buckling Distortion in Welding of a Thin Wall Aluminum Butt Joint

Author(s):  
Sanaz Yazdanparast ◽  
Mohsen Asle Zaeem ◽  
Iraj Rajabi

In this paper, global welding buckling distortion of a thin wall aluminum butt joint is investigated. To determine longitudinal residual stresses, a thermo-elastoplastic model is employed; analysis of thermal model and elastic-viscoplastic (Anand) model are decoupled. By using birth and death element method and time dependent model, molten puddle motion (speed of welding) is modeled. Three dimensional nonlinear-transient heat flow analysis has been used to obtain temperature distribution. By applying thermal results and using three dimensional Anand elastic-viscoplastic model, stress and deformation distributions are obtained. Residual stresses are applied on a structural model and by using eigenvalue methods, global buckling instability of butt welded joint is determined. The result of buckling investigation in the numerical model is compared with the result of an experiment.

2006 ◽  
Vol 519-521 ◽  
pp. 1187-1192
Author(s):  
Mohsen Asle Zaeem ◽  
M.R. Nami ◽  
I. Rajabi ◽  
M.H. Kadivar

In this paper global welding buckling distortion of a thin wall aluminum T joint is investigated. A thermo-elastoplastic model is employed to determine longitudinal residual stresses; analysis of thermal model and elastic-viscoplastic (Anand) model are decoupled. Molten puddle motion (speed of welding) is modeled by using birth and death element method and time dependent model. Three dimensional nonlinear-transient heat flow analysis has been used to obtain temperature distribution, and then by applying thermal results and using three dimensional Anand elastic-viscoplastic model, stress and deformation distributions are obtained. By applying residual stresses on a structural model and using eigenvalue methods, global buckling instability of the welded structure is determined. Some experiments are done for validating the numerical results.


Author(s):  
M. Asle Zaeem ◽  
M. R. Nami ◽  
M. H. Kadivar

In this paper global welding buckling distortion of a thin wall aluminum T joint is investigated. A thermo-elastoplastic model is employed to determine longitudinal residual stresses; analysis of thermal model and elastic-viscoplastic (Anand) model are decoupled. Molten puddle motion (speed of welding) is modeled by using birth and death element method and time dependent model. Three dimensional nonlinear-transient heat flow analysis has been used to obtain temperature distribution, and then by applying thermal results and using three dimensional Anand elastic-viscoplastic model, stress and deformation distributions are obtained. By applying residual stresses on a structural model and using eigenvalue methods, global buckling instability of the welded structure is determined.


Author(s):  
Xian-Kui Zhu ◽  
Rick Wang

Mechanical dents often occur in transmission pipelines, and are recognized as one of major threats to pipeline integrity because of the potential fatigue failure due to cyclic pressures. With matured in-line-inspection (ILI) technology, mechanical dents can be identified from the ILI runs. Based on ILI measured dent profiles, finite element analysis (FEA) is commonly used to simulate stresses and strains in a dent, and to predict fatigue life of the dented pipeline. However, the dent profile defined by ILI data is a purely geometric shape without residual stresses nor plastic deformation history, and is different from its actual dent that contains residual stresses/strains due to dent creation and re-rounding. As a result, the FEA results of an ILI dent may not represent those of the actual dent, and may lead to inaccurate or incorrect results. To investigate the effect of residual stress or plastic deformation history on mechanics responses and fatigue life of an actual dent, three dent models are considered in this paper: (a) a true dent with residual stresses and dent formation history, (b) a purely geometric dent having the true dent profile with all stress/strain history removed from it, and (c) a purely geometric dent having an ILI defined dent profile with all stress/strain history removed from it. Using a three-dimensional FEA model, those three dents are simulated in the elastic-plastic conditions. The FEA results showed that the two geometric dents determine significantly different stresses and strains in comparison to those in the true dent, and overpredict the fatigue life or burst pressure of the true dent. On this basis, suggestions are made on how to use the ILI data to predict the dent fatigue life.


Author(s):  
W. T. Tiow ◽  
M. Zangeneh

The development and application of a three-dimensional inverse methodology is presented for the design of turbomachinery blades. The method is based on the mass-averaged swirl, rV~θ distribution and computes the necessary blade changes directly from the discrepancies between the target and initial distributions. The flow solution and blade modification converge simultaneously giving the final blade geometry and the corresponding steady state flow solution. The flow analysis is performed using a cell-vertex finite volume time-marching algorithm employing the multistage Runge-Kutta integrator in conjunction with accelerating techniques (local time stepping and grid sequencing). To account for viscous effects, dissipative forces are included in the Euler solver using the log-law and mixing length models. The design method can be used with any existing solver solving the same flow equations without any modifications to the blade surface wall boundary condition. Validation of the method has been carried out using a transonic annular turbine nozzle and NASA rotor 67. Finally, the method is demonstrated on the re-design of the blades.


2013 ◽  
Vol 729 ◽  
pp. 702-731 ◽  
Author(s):  
A. I. Ruban ◽  
M. A. Kravtsova

AbstractIn this paper we study the three-dimensional perturbations produced in a hypersonic boundary layer by a small wall roughness. The flow analysis is performed under the assumption that the Reynolds number, $R{e}_{0} = {\rho }_{\infty } {V}_{\infty } L/ {\mu }_{0} $, and Mach number, ${M}_{\infty } = {V}_{\infty } / {a}_{\infty } $, are large, but the hypersonic interaction parameter, $\chi = { M}_{\infty }^{2} R{ e}_{0}^{- 1/ 2} $, is small. Here ${V}_{\infty } $, ${\rho }_{\infty } $ and ${a}_{\infty } $ are the flow velocity, gas density and speed of sound in the free stream, ${\mu }_{0} $ is the dynamic viscosity coefficient at the ‘stagnation temperature’, and $L$ is the characteristic distance the boundary layer develops along the body surface before encountering a roughness. We choose the longitudinal and spanwise dimensions of the roughness to be $O({\chi }^{3/ 4} )$ quantities. In this case the flow field around the roughness may be described in the framework of the hypersonic viscous–inviscid interaction theory, also known as the triple-deck model. Our main interest in this paper is the nonlinear behaviour of the perturbations. We study these by means of numerical solution of the triple-deck equations, for which purpose a modification of the ‘skewed shear’ technique suggested by Smith (United Technologies Research Center Tech. Rep. 83-46, 1983) has been used. The technique requires global iterations to adjust the viscous and inviscid parts of the flow. Convergence of such iterations is known to be a major problem in viscous–inviscid calculations. In order to achieve improved stability of the method, both the momentum equation for the viscous part of the flow, and the equations describing the interaction with the flow outside the boundary layer, are treated implicitly in this study. The calculations confirm the fact that in this sort of flow the perturbations are capable of propagating upstream in the boundary layer, resulting in a perturbation field which surrounds the roughness on all sides. We found that the perturbations decay rather fast with the distance from the roughness everywhere except in the wake behind the roughness. We found that if the height of the roughness is small, then the perturbations also decay in the wake, though much more slowly than outside the wake. However, if the roughness height exceeds some critical value, then two symmetric counter-rotating vortices form in the wake. They appear to support themselves and grow as the distance from the roughness increases.


1984 ◽  
Vol 106 (2) ◽  
pp. 511-515 ◽  
Author(s):  
E. A. Baskharone

A three-dimensional inviscid flow analysis in the combined scroll-nozzle system of a radial inflow turbine is presented. The coupling of the two turbine components leads to a geometrically complicated, multiply-connected flow domain. Nevertheless, this coupling accounts for the mutual effects of both elements on the three-dimensional flow pattern throughout the entire system. Compressibility effects are treated for an accurate prediction of the nozzle performance. Different geometrical configurations of both the scroll passage and the nozzle region are investigated for optimum performance. The results corresponding to a sample scroll-nozzle configuration are verified by experimental measurements.


2012 ◽  
Vol 424-425 ◽  
pp. 598-602 ◽  
Author(s):  
You Min Wang ◽  
Chun Zhao ◽  
Jian Hua Zhang

In order to improve design performance, shorten development cycles, reduce production cost, we design and research the forklift hydraulic system, developed forklift hydraulic system diagram. Forklift virtual prototype’s 3-D solid modeling is designed by Pro / E three-dimensional software, and imported into the ADAMS environment. Add constraints and drivers exert the control function separately to the tilting cylinder and lifting cylinder, carry on the kinematics simulation. Through the analysis to the compound motion actuation control functional arrangement、the compound motion speed graph、the gate’s tilt angle graph、the tilting cylinder stress graph and the lifting cylinder stress graph, he simulation result indicated: each cylinder design is reasonable, the movement without interference,the reasonable work scope satisfied to the work size request


1985 ◽  
Author(s):  
T. BARBER ◽  
G. MULLER ◽  
S. RAMSAY ◽  
E. MURMAN

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