scholarly journals Large-Scale Welding Process Simulation by GPU Parallelized Computing

2021 ◽  
Vol 100 (11) ◽  
pp. 359-370
Author(s):  
HUI HUANG ◽  
◽  
JIAN CHEN ◽  
ZHILI FENG ◽  
HUI-PING WANG ◽  
...  
Keyword(s):  
Residual Stress ◽  
Large Scale ◽  
Welding Process ◽  
Computational Design ◽  
Nuclear Industry ◽  
Welding Distortion ◽  
Deformation Pattern ◽  
Processing Unit ◽  
Automotive Manufacturing ◽  
Welding Processes

The computational design of industrially relevant welded structures is extremely time consuming due to coupled physics and high nonlinearity. Previously, most welding distortion and residual stress simulations have been limited to small coupons and reduced order (from three-dimensional [3D] to two-dimensional [2D]), or inherent strain approximations were used for large structures. In this current study, an explicit finite element code based on a graphics processing unit was utilized to perform 3D transient thermomechanical simulation of structural components during welding. Laser brazing of aluminum alloy panels as representative of automotive manufacturing scenarios was simulated to predict out-of-plane distortion under different clamping conditions. The predicted deformation pattern and magnitude were validated by laser scanning data of physical assemblies. In addition, the code was used to investigate residual stresses developed during multipass arc welding of a nuclear industry pressurizer surge nozzle and subsequent welding repair where a 3D simulation was necessary. Taking the experimental data as reference, the 3D model predicted better residual stress distribution than a typical 2D asymmetrical model. Stress evolution in welding repair was also presented and discussed in this study. The efficient numerical model made it feasible to use integrated computational welding engineering to simulate welding processes for large-scale structures.

scholarly journals Effect of Trailing Intensive Cooling on Residual Stress and Welding Distortion of Friction Stir Welded 2060 Al-Li Alloy

2018 ◽  
Vol 37 (5) ◽  
pp. 397-403 ◽  
Author(s):  
Shude Ji ◽  
Zhanpeng Yang ◽  
Quan Wen ◽  
Yumei Yue ◽  
Liguo Zhang
Keyword(s):  
Residual Stress ◽  
Friction Stir Welding ◽  
Plastic Strain ◽  
Welding Process ◽  
Butt Joint ◽  
Welding Distortion ◽  
Welding Temperature ◽  
Friction Stir ◽  
Numerical Simulation Methods ◽  
Conventional Cooling

AbstractTrailing intensive cooling with liquid nitrogen has successfully applied to friction stir welding of 2 mm thick 2060 Al-Li alloy. Welding temperature, plastic strain, residual stress and distortion of 2060 Al-Li alloy butt-joint are compared and discussed between conventional cooling and trailing intensive cooling using experimental and numerical simulation methods. The results reveal that trailing intensive cooling is beneficial to shrink high temperature area, reduce peak temperature and decrease plastic strain during friction stir welding process. In addition, the reduction degree of plastic strain outside weld is smaller than that inside weld. Welding distortion presents an anti-saddle shape. Compared with conventional cooling, the reductions of welding distortion and longitudinal residual stresses of welding joint under intense cooling reach 47.7 % and 23.8 %, respectively.

scholarly journals Prediction of Residual Stresses in a Multipass Pipe Weld by a Novel 3D Finite Element Approach

2018 ◽  
Author(s):  
Hui Huang ◽  
Jian Chen ◽  
Blair Carlson ◽  
Hui-Ping Wang ◽  
Paul Crooker ◽  
...  
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
High Performance ◽  
Large Scale ◽  
Graphics Processing Unit ◽  
Computational Cost ◽  
Three Dimensional ◽  
Processing Unit ◽  
Girth Welds ◽  
Welding Processes

Due to enormous computation cost, current residual stress simulation of multipass girth welds are mostly performed using two-dimensional (2D) axisymmetric models. The 2D model can only provide limited estimation on the residual stresses by assuming its axisymmetric distribution. In this study, a highly efficient thermal-mechanical finite element code for three dimensional (3D) model has been developed based on high performance Graphics Processing Unit (GPU) computers. Our code is further accelerated by considering the unique physics associated with welding processes that are characterized by steep temperature gradient and a moving arc heat source. It is capable of modeling large-scale welding problems that cannot be easily handled by the existing commercial simulation tools. To demonstrate the accuracy and efficiency, our code was compared with a commercial software by simulating a 3D multi-pass girth weld model with over 1 million elements. Our code achieved comparable solution accuracy with respect to the commercial one but with over 100 times saving on computational cost. Moreover, the three-dimensional analysis demonstrated more realistic stress distribution that is not axisymmetric in hoop direction.

scholarly journals Comparative study of welding deformation of a stiffened panel under various welding procedures

2017 ◽  
Vol 233 (1) ◽  
pp. 182-191 ◽  
Author(s):  
Zhen Chen ◽  
Qi Yu ◽  
Yu Luo ◽  
R Ajit Shenoi
Keyword(s):  
Large Scale ◽  
Welding Process ◽  
Production Quality ◽  
Welding Distortion ◽  
Stiffened Panel ◽  
Welding Deformation ◽  
Large Scale Structures ◽  
Improve Production Quality ◽  
Scale Structures ◽  
Welding Procedure

The welding distortions of large-scale structures are extraordinary complicated. If an effective tool of predicting welding distortion is available, then marine design and manufacturing engineers can use this to improve production quality and reduce costs. This article focuses on the comparative studies of welding procedure of a stiffened panel. An efficient thermal elasto-plastic finite element method–based procedure is developed to predict the welding deformation and residual stress of structures. A combined shell/solid model is adopted to enhance modeling and calculation efficiency. The welding process of a stiffened panel is simulated. Three welding procedures of simultaneous, successive and bidirectional welding are studied. The results show that welding distortion can be well controlled by adjusting the welding procedure.

Finite Element Simulation of Welding of Large Structures

1992 ◽  
Vol 114 (4) ◽  
pp. 441-451 ◽  
Author(s):  
S. Brown ◽  
H. Song
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Finite Element Simulation ◽  
Three Dimensional ◽  
Mechanical Analysis ◽  
Welding Distortion ◽  
Surrounding Structure ◽  
Element Simulation ◽  
Weld Distortion ◽  
Welding Processes

Current simulations of welding distortion and residual stress have considered only the local weld zone. A large elastic structure surrounding a weld, however, can couple with the welding operation to produce a final weld state much different from that resulting when a smaller structure is welded. The effect of this coupling between structure and weld has the potential of dominating the final weld distortion and residual stress state. This paper employs both two-and three-dimensional finite element models of a circular cylinder and stiffening ring structure to investigate the interaction of a large structure on weld parameters such as weld gap clearance (fitup) and fixturing. The finite element simulation considers the full thermo-mechanical problem, uncoupling the thermal from the mechanical analysis. The thermal analysis uses temperature-dependent material properties, including latent heat and nonlinear heat convection and radiation boundary conditions. The mechanical analysis uses a thermal-elastic-plastic constitutive model and an element “birth” procedure to simulate the deposition of weld material. The effect of variations of weld gap clearance, fixture positions, and fixture types on residual stress states and distortion are examined. The results of these analyses indicate that this coupling effect with the surrounding structure should be included in numerical simulations of welding processes, and that full three-dimensional models are essential in predicting welding distortion. Elastic coupling with the surrounding structure, weld fitup, and fixturing are found to control residual stresses, creating substantial variations in highest principal and hydrostatic stresses in the weld region. The position and type of fixture are shown to be primary determinants of weld distortion.

Design Support Tool for Prediction of Welding Distortion in Multiply Stiffened Plate Structures: Experimental and Computational Investigation

2005 ◽  
Vol 21 (04) ◽  
pp. 219-234
Author(s):  
Duncan Camilleri ◽  
Tugrul Comlekci ◽  
Thomas G. F. Gray
Keyword(s):  
Large Scale ◽  
Computational Models ◽  
Plane Deformation ◽  
Computational Prediction ◽  
Welding Distortion ◽  
Plate Structures ◽  
Welded Structures ◽  
Welding Sequence ◽  
Out Of Plane ◽  
Welding Processes

Many industries, such as shipbuilding, concerned with the fabrication of fusionwelded plate structures, face increasing challenges to produce lightweight structures. This design requirement is commonly met by using thin-plate, multiply stiffened, welded structures, but severe difficulties and high rectification costs are frequently incurred, related to the evolution of out-of-plane deformations. The overall scope of this study is to improve the applicability of computational prediction of distortion by providing simple and adaptable methodologies, which can be readily validated through experience of application in the industrial context. These methods are designed to be computationally economic and robust, and they are also generic with respect to material properties, welding processes, and thickness. The aim is to provide design engineers with the tools to explore alternative structural and process parameters and hence to find out if the outcomes will be acceptable, prior to embarking on manufacturing operations typical of large-scale welded structures. The validity of the simulations was investigated via full-scale tests where several filletwelded 100 mm × 6 mmstiffeners were attached to 4 m × 1.5 m × 5 mmthick plates, according to different sequences. The computational models were used to optimize the welding scheme with respect to minimum out-of-plane deformation and welding sequence.

Residual Stresses Measurement in Various Joint Weldments

2013 ◽  
Author(s):  
Xavier Ficquet ◽  
Sayeed Hossain ◽  
Ed J. Kingston
Keyword(s):  
Experimental Data ◽  
Residual Stress ◽  
Structural Integrity ◽  
Stress Measurement ◽  
Nuclear Industry ◽  
Residual Stress Measurement ◽  
Stress Measurements ◽  
First Case ◽  
Offshore Industry ◽  
Welding Processes

Published experimental data from residual stress measurements are generally limited or difficult to find. Experimental data in the offshore industry are even more scarce and difficult to access to. The oil and gas industry can benefit from research done in other industries. For example, the nuclear industry has published a multitude of residual stress measurements that could be beneficial to the offshore industry, gaining more understanding and confidence in the structural integrity of critical components. For the past year VEQTER Ltd has been developing a web access database for storing and comparing residual stress measurement and modelling results. This paper presents a comparison of through thickness residual stress measurement results that are published. The first case will show numerous measurements using different techniques on girth welded joints. Then, measurements on the temper bead welding processes which have been developed to simulate the tempering effect of post-weld heat treatment will be presented and compared with cladding. Finally, comparison of residual stress measurements on T-section plate fillet weld will be made.

Numerical Modelling of Residual Stress and Distortion in Welded Thin Steel Plates

2008 ◽  
Author(s):  
M. Tsunori ◽  
C. M. Davies ◽  
D. Dye ◽  
K. M. Nikbin
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Welding Process ◽  
Steel Plates ◽  
Thin Plates ◽  
Welding Distortion ◽  
Butt Welding ◽  
Thin Steel ◽  
Out Of Plane ◽  
Plate Size

Current trends in ship design are to reduce panel thickness in order to minimise the vessels weight and hence maximise speed. These panels are manufactured through butt welding thin steel plates with the addition of fillet welded stiffeners. Excessive distortions are exhibited in these thin plates due to the welding process, resulting in major rectification or re-manufacturing costs. The aim of this study is to develop a tool to predict welding residual stresses and distortions in order to understand their governing factors, and thus enabling the optimum fabrication processes to be realized to minimise welding distortion. Finite element simulations are performed of the butt and fillet welding process in 4 mm thick plates of ferritic DH-36 steel and the residual stresses and distortions are predicted. Thermal and residual stress profiles are verified against experimental measurements. The effects of plate and stiffener dimensions are examined numerically. In addition, a sensitivity analysis has been carried out to quantify the effects of restraint on a small butt welded plate. It is concluded that final distortion may be severely reduced, in the plate size considered, if only an out-of-plane constraint is imposed on the plate’s surfaces. Further welding experiments are required to validate these findings.

Fast Simulation for Multi-Pass Welding Process Using Iterative Substructure Method: Investigation of Optimization and Efficient Computation

2014 ◽  
Author(s):  
Akira Maekawa ◽  
Atsushi Kawahara ◽  
Hisashi Serizawa ◽  
Hidekazu Murakawa
Keyword(s):  
Residual Stress ◽  
Power Plants ◽  
Welding Process ◽  
Computation Time ◽  
Efficient Computation ◽  
Element Analysis ◽  
Substructure Method ◽  
Elastic Plastic ◽  
Plastic Analysis ◽  
Welding Processes

Residual stress caused by welding processes affects characteristics of strength and fracture of equipment and piping in power plants. Numerical thermal elastic-plastic analysis is a powerful tool to evaluate weld residual stress in actual plants. However, the conventional three-dimensional precise analysis for a welding process such as multi-pass welding, machining and thermal treatment requires enormous computation time though it can provide accurate results. In this paper, the finite element analysis code based on the iterative substructure method that was developed to carry out thermal elastic-plastic analysis efficiently, with both high computational speed and accuracy, was proposed to simulate the welding process of plant equipment and piping. Furthermore, optimization of the proposed analysis code was examined and the computational efficiency and accuracy were also evaluated.

Effect of Weld on Axial Buckling of Cylindrical Shells

2010 ◽  
Vol 139-141 ◽  
pp. 171-175 ◽  
Author(s):  
Zhou Fang ◽  
Zhi Ping Chen ◽  
Chu Lin Lu ◽  
Ming Zeng
Keyword(s):  
Residual Stress ◽  
Critical Stress ◽  
Cylindrical Shells ◽  
Welding Process ◽  
Circumferential Welds ◽  
Axial Buckling ◽  
Oil Storage ◽  
Stress And Deformation ◽  
Welding Processes ◽  
Residual Stress And Deformation

Large oil storage tank (oil tank for short) shells are vulnerable to buckling damage when suffering the seismic loads. Numerical simulation analysis was taken to estimate the effects of the weld form, number and their location to axial buckling stress of cylindrical shells, considering not only the characteristic of welding processes, but also the effects probably caused by magnitude of residual stress and deformation on elephant foot buckling to oil tanks. It is revealed that the existence of circumferential welds had obvious negative effect on axial buckling critical stress compared with the structure without welds, while the effects of weld number and location were not as much; longitudinal welds had no visible effect on axial buckling critical stress; controlling the residual stress and deformation range caused by circumferential welds should be the key point during the tanks welding process.

Numerical simulation of welding-induced residual stress in fusion welding process using adaptive volumetric heat source

2014 ◽  
Vol 228 (16) ◽  
pp. 2960-2972 ◽  
Author(s):  
S Singh ◽  
N Yadaiah ◽  
S Bag ◽  
S Pal
Keyword(s):  
Residual Stress ◽  
Numerical Model ◽  
Heat Source ◽  
Measurement Errors ◽  
High Performance ◽  
Welding Process ◽  
Fusion Welding ◽  
Volumetric Heat Source ◽  
Welding Processes

The mechanical properties of a weldment structure are influenced by the level of residual stress generated during fusion welding process. The experimental determination of residual stress is cumbersome and not free from measurement errors. A sophisticated numerical model is relatively easy approach to predict residual stress due to the advancement of high performance computational technology. However, the integration of all process physics to make a sophisticated numerical model is ever demanding. The present work is motivated in that direction and involves a finite element based numerical model for simulation of welding-induced residual stresses. A thermal model using adaptive volumetric heat source has been used to estimate temperature distribution. Subsequently, the thermal history is used to perform stress analysis for butt welded plates using three different fusion welding processes. The material behaviour is assumed as elasto-plastic in nature. The calculated results and their trend have been validated with experimental results available in open literature.

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