Finite Element Simulation of Laser Beam Welding Induced Residual Stresses and Distortions in a T-Joint Configuration for Aeronautic Structures

2009 ◽  
Author(s):  
Muhammad Zain-ul-abdein ◽  
Daniel Ne´lias ◽  
Jean-Franc¸ois Jullien ◽  
Dominique Deloison
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Laser Beam ◽  
Boundary Conditions ◽  
Laser Beam Welding ◽  
Temperature Fields ◽  
Heat Transfer Analysis ◽  
Small Scale ◽  
Joint Configuration ◽  
Simulation Results

Laser beam welding has found its application in the aircraft industry for the fabrication of fuselage panels in a T-joint configuration. However, the inconveniences like distortions and residual stresses are inevitable consequences of welding. The effort is made in this work to experimentally measure and numerically simulate the distortions induced by laser beam welding of a T-joint with industrially used thermal and mechanical boundary conditions on the thin sheets of aluminium 6056-T4. Several small scale experiments were carried out with various instrumentations to establish a database necessary to verify the simulation results. Finite element (FE) simulation is performed with Abaqus and the conical heat source is programmed in FORTRAN. Heat transfer analysis is performed to achieve the required weld pool geometry and temperature fields. Mechanical analysis is then performed with industrial loading and boundary conditions so as to predict the distortion and the residual stress pattern. A good agreement is found amongst the experimental and simulation results.

scholarly journals Small Caliber Bulletproof Test of Warships’ Hulls

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3848
Author(s):  
Radosław Kiciński ◽  
Andrzej Kubit
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Boundary Conditions ◽  
Finite Element Method Simulation ◽  
Material Model ◽  
Experimental Results ◽  
Material Constants ◽  
Steel Core ◽  
Calculation Results ◽  
Simulation Results

The article presents the characteristics of 1.3964 steel and the results of firing a 7.62 mm projectile with a steel core. A simplified Johnson–Cook material model for steel and projectile was used. Then, a FEM (finite element method) simulation was prepared to calibrate the material constants and boundary conditions necessary to be used in simulations of the entire hull model. It was checked how projectile modeling affects the FEM calculation results. After obtaining the simulation results consistent with the experimental results, using the model of a modern minehunter, the resistance of the ship’s hull to penetration by a small-caliber projectile was tested.

Laser beam welding of dissimilar stainless steels in a fillet joint configuration

2012 ◽  
Vol 212 (4) ◽  
pp. 856-867 ◽  
Author(s):  
M.M.A. Khan ◽  
L. Romoli ◽  
M. Fiaschi ◽  
G. Dini ◽  
F. Sarri
Keyword(s):  
Laser Beam ◽  
Stainless Steels ◽  
Laser Beam Welding ◽  
Joint Configuration ◽  
Fillet Joint

Study of the Effect of Boundary Conditions on Residual Stresses in Welding Using Element Birth and Element Movement Techniques

2003 ◽  
Author(s):  
Ihab F. Z. Fanous ◽  
Maher Y. A. Younan ◽  
Abdalla S. Wifi
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Boundary Conditions ◽  
Welding Process ◽  
Computation Time ◽  
3D Models ◽  
The Other ◽  
3D Analysis ◽  
The Media ◽  
Element Movement

The structure in which the welding process is performed highly affects the residual stresses generated in the welding. This effect is simulated by choosing the appropriate boundary conditions in modeling the welding process. The major parameters of the boundary conditions are the method by which the base metal is being fixed and the amount of heat being applied through the torch. Other parameters may include the coefficients of thermal heat loss from the plate which may simulate the media in which the welding is taking place. In modeling the welding process, 2D forms of approximation were developed in analyzing most of the models of such problem. 3D models analyzing the welding process were developed in limited applications due to its high computation time and cost. With the development of new finite element tools, namely the element movement technique developed by the authors, full 3D analysis of the welding process is becoming in hand. In the present work, three different boundary conditions shall be modeled companng their effect on the welding. These boundary conditions shall be applied to two models of the welding process: one using the element birth technique and the other using the element movement technique showing the similarity in their responses verifying the effectiveness of the latter being accomplished in a shorter time.

Estimation of Residual Stresses in Steel Welded Joints Using Three Dimensional Finite Element Analysis

2018 ◽  
Author(s):  
Shivdayal Patel ◽  
B. P. Patel ◽  
Suhail Ahmad
Keyword(s):  
Residual Stress ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Residual Stresses ◽  
Boundary Conditions ◽  
Welding Speed ◽  
Welded Joints ◽  
Plate Thickness ◽  
Welding Process ◽  
Element Analysis

Welding is one of the most used joining methods in the ship industry. However, residual stresses are induced in the welded joints due to the rapid heating and cooling leading to inhomogenously distributed dimensional changes and non-uniform plastic and thermal strains. A number of factors, such as welding speed, boundary conditions, weld geometry, weld thickness, welding current/voltage, number of weld passes, pre-/post-heating etc, influence the residual stress distribution. The main aim of this work is to estimate the residual stresses in welded joints through finite element analysis and to investigate the effects of boundary conditions, welding speed and plate thickness on through the thickness/surface distributions of residual stresses. The welding process is simulated using 3D Finite element model in ABAQUS FE software in two steps: 1. Transient thermal analysis and 2. Quasi-static thermo-elasto-plastic analysis. The normal residual stresses along and across the weld in the weld tow region are found to be significant with nonlinear distribution. The residual stresses increase with the increase in the thickness of the plates being welded. The nature of the normal residual stress along the weld is found to be tensile-compressive-tensile and the nature of normal residual stress across the weld is found to be tensile along the thickness direction.

Prediction of laser beam welding-induced distortions and residual stresses by numerical simulation for aeronautic application

2009 ◽  
Vol 209 (6) ◽  
pp. 2907-2917 ◽  
Author(s):  
Muhammad Zain-ul-Abdein ◽  
Daniel Nelias ◽  
Jean-François Jullien ◽  
Dominique Deloison
Keyword(s):  
Numerical Simulation ◽  
Residual Stresses ◽  
Laser Beam ◽  
Laser Beam Welding

Laser Welding Simulations of Stainless Steel Joints Using Finite Element Analysis

2011 ◽  
Vol 383-390 ◽  
pp. 6225-6230
Author(s):  
K.R. Balasubramanian ◽  
T. Suthakar ◽  
K. Sankaranarayanasamy ◽  
G. Buvanashekaran
Keyword(s):  
Finite Element ◽  
Stainless Steel ◽  
Laser Beam ◽  
Laser Welding ◽  
Laser Beam Welding ◽  
Welding Process ◽  
Weld Bead ◽  
Heat Of Fusion ◽  
T Joints ◽  
Finite Element Software

Laser beam welding (LBW) is a fusion joining process that uses the energy from a laser beam to melt and subsequently crystallize a metal, resulting in a bond between parts. In this study, finite element method (FEM) is used for predicting the weld bead profile of laser welding butt, lap and T-joints. A three-dimensional finite element model is used to analyze the temperature distribution weld bead shape for different weld configurations produced by the laser welding process. In the model temperature-dependent thermo physical properties of AISI304 stainless steel, effect of latent heat of fusion and convective and radiative boundary conditions are incorporated. The heat input to the FEM model is assumed to be a 3D conical Gaussian heat source. The finite element software SYSWELD is employed to obtain the numerical results. The computed weld bead profiles for butt, lap and T-joints are compared with the experimental profiles and are found to be in agreement.

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