scholarly journals Influence of Restraint Conditions on Welding Residual Stresses in H-Type Cracking Test Specimens

Materials ◽  
2019 ◽  
Vol 12 (17) ◽  
pp. 2700 ◽  
Author(s):  
Jiamin Sun ◽  
Jonas Hensel ◽  
Thomas Nitschke-Pagel ◽  
Klaus Dilger
Keyword(s):  
Numerical Simulation ◽  
Tensile Stress ◽  
Residual Stresses ◽  
Experimental Method ◽  
Large Scale ◽  
Small Scale ◽  
Welded Structures ◽  
The Real ◽  
Restrained Cracking ◽  
Welding Processes

From the viewpoint of mechanics, weld cracking tends to occur if the induced tensile stress surpasses a certain value for the particular materials and the welding processes. Welding residual stresses (WRS) can be profoundly affected by the restraint conditions of the welded structures. For estimating the tendency of weld cracking, the small-scale H-type slit joints have been widely used for cracking tests. However, it is still hard to decide whether the real large-scale component can also be welded without cracking even though the tested weld cracking specimens on the laboratory scale can be welded without cracking. In this study, the intensity of restraint which quantitatively indicates how much a joint is restrained is used. The influence of restraint condition (intensity of restraint) on WRS is systematically investigated using both the numerical simulation and the experimental method. The achievement obtained in the current work is very beneficial to design effective H-type self-restrained cracking test specimens for evaluating the sensitivity of the material and the welding procedures for weld cracking in the real large-scale components.

Analysis of circumferentially welded thin-walled cylinders to study the effects of tack weld orientations and joint root opening on residual stress fields

2009 ◽  
Vol 223 (5) ◽  
pp. 1037-1049 ◽  
Author(s):  
N U Dar ◽  
E M Qureshi ◽  
A M Malik ◽  
M M I Hammouda ◽  
R A Azeem
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Arc Welding ◽  
Operating Conditions ◽  
Stress Fields ◽  
Welded Structures ◽  
Prime Concern ◽  
Thin Walled ◽  
Tack Weld ◽  
Welding Processes

In recent years, the demand for resilient welded structures with excellent in-service load-bearing capacity has been growing rapidly. The operating conditions (thermal and/or structural loads) are becoming more stringent, putting immense pressure on welding engineers to secure excellent quality welded structures. The local, non-uniform heating and subsequent cooling during the welding processes cause complex thermal stress—strain fields to develop, which finally leads to residual stresses, distortions, and their adverse consequences. Residual stresses are of prime concern to industries producing weld-integrated structures around the globe because of their obvious potential to cause dimensional instability in welded structures, and contribute to premature fracture/failure along with significant reduction in fatigue strength and in-service performance of welded structures. Arc welding with single or multiple weld runs is an appropriate and cost-effective joining method to produce high-strength structures in these industries. Multi-field interaction in arc welding makes it a complex manufacturing process. A number of geometric and process parameters contribute significant stress levels in arc-welded structures. In the present analysis, parametric studies have been conducted for the effects of a critical geometric parameter (i.e. tack weld) on the corresponding residual stress fields in circumferentially welded thin-walled cylinders. Tack weld offers considerable resistance to the shrinkage, and the orientation and size of tacks can altogether alter stress patterns within the weldments. Hence, a critical analysis for the effects of tack weld orientation is desirable.

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 Anisotropic Characteristics of Turbulence Dissipation in Swirling Flow: A Direct Numerical Simulation Study

2015 ◽  
Vol 2015 ◽  
pp. 1-9 ◽  
Author(s):  
Xingtuan Yang ◽  
Nan Gui ◽  
Gongnan Xie ◽  
Jie Yan ◽  
Jiyuan Tu ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Energy Dissipation ◽  
Direct Numerical Simulation ◽  
Large Scale ◽  
Isotropic Turbulence ◽  
Vortex Breakdown ◽  
Swirling Flow ◽  
Turbulent Energy ◽  
Swirling Flows ◽  
Small Scale

This study investigates the anisotropic characteristics of turbulent energy dissipation rate in a rotating jet flow via direct numerical simulation. The turbulent energy dissipation tensor, including its eigenvalues in the swirling flows with different rotating velocities, is analyzed to investigate the anisotropic characteristics of turbulence and dissipation. In addition, the probability density function of the eigenvalues of turbulence dissipation tensor is presented. The isotropic subrange of PDF always exists in swirling flows relevant to small-scale vortex structure. Thus, with remarkable large-scale vortex breakdown, the isotropic subrange of PDF is reduced in strongly swirling flows, and anisotropic energy dissipation is proven to exist in the core region of the vortex breakdown. More specifically, strong anisotropic turbulence dissipation occurs concentratively in the vortex breakdown region, whereas nearly isotropic turbulence dissipation occurs dispersively in the peripheral region of the strong swirling flows.

Scaling Effect on Dynamic Impact Response of Structures in Fluid Fields

2013 ◽  
Author(s):  
Zhongheng Guo ◽  
Lingyu Sun ◽  
Taikun Wang ◽  
Junmin Du ◽  
Han Li ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Dimensional Analysis ◽  
Large Scale ◽  
Scaling Laws ◽  
Scaling Law ◽  
Fluid Pressure ◽  
Structural Safety ◽  
Scale Model ◽  
Small Scale ◽  
Water Tank

At the conceptual design phase of a large-scale underwater structure, a small-scale model in a water tank is often used for the experimental verification of kinematic principles and structural safety. However, a general scaling law for structure-fluid interaction (FSI) problems has not been established. In the present paper, the scaling laws for three typical FSI problems under the water, rigid body moves at a given kinematic equation or is driven by time-dependent fluids with given initial condition, as well as elastic-plastic body moves and then deforms subject to underwater impact loads, are investigated, respectively. First, the power laws for these three types of FSI problems were derived by dimensional analysis method. Then, the laws for the first two types were verified by numerical simulation. In addition, a multipurpose small-scale water sink test device was developed for numerical model updating. For the third type of problem, the dimensional analysis is no longer suitable due to its limitation on identifying the fluid pressure and structural stress, a simulation-based procedure for dynamics evaluation of large-scale structure was provided. The results show that, for some complex FSI problems, if small-scale prototype is tested safely, it doesn’t mean the full-scale product is also safe if both their pressure and stress are the main concerns, it needs further demonstration, at least by numerical simulation.

scholarly journals A study of the flow-field evolution and mixing in a planar turbulent jet using direct numerical simulation

2002 ◽  
Vol 450 ◽  
pp. 377-407 ◽  
Author(s):  
S. A. STANLEY ◽  
S. SARKAR ◽  
J. P. MELLADO
Keyword(s):  
Numerical Simulation ◽  
Flow Field ◽  
Direct Numerical Simulation ◽  
Large Scale ◽  
Computational Study ◽  
Practical Interest ◽  
Small Scale ◽  
Mixing Process ◽  
Mean Velocity ◽  
Small Scales

Turbulent plane jets are prototypical free shear flows of practical interest in propulsion, combustion and environmental flows. While considerable experimental research has been performed on planar jets, very few computational studies exist. To the authors' knowledge, this is the first computational study of spatially evolving three-dimensional planar turbulent jets utilizing direct numerical simulation. Jet growth rates as well as the mean velocity, mean scalar and Reynolds stress profiles compare well with experimental data. Coherency spectra, vorticity visualization and autospectra are obtained to identify inferred structures. The development of the initial shear layer instability, as well as the evolution into the jet column mode downstream is captured well.The large- and small-scale anisotropies in the jet are discussed in detail. It is shown that, while the large scales in the flow field adjust slowly to variations in the local mean velocity gradients, the small scales adjust rapidly. Near the centreline of the jet, the small scales of turbulence are more isotropic. The mixing process is studied through analysis of the probability density functions of a passive scalar. Immediately after the rollup of vortical structures in the shear layers, the mixing process is dominated by large-scale engulfing of fluid. However, small-scale mixing dominates further downstream in the turbulent core of the self-similar region of the jet and a change from non-marching to marching PDFs is observed. Near the jet edges, the effects of large-scale engulfing of coflow fluid continue to influence the PDFs and non-marching type behaviour is observed.

Molten Pool in Welding Processes: Phenomenological vs Fluid-Dynamic Numerical Simulation Approach

2017 ◽  
Vol 884 ◽  
pp. 26-40 ◽  
Author(s):  
Paolo Ferro
Keyword(s):  
Numerical Simulation ◽  
Residual Stresses ◽  
Fusion Zone ◽  
Weld Pool ◽  
Fluid Dynamic ◽  
Subsequent Development ◽  
Grain Structure ◽  
Pool Shape ◽  
Welding Processes ◽  
Weld Pool Shape

The metallurgical and mechanical properties of fusion welded joints are influenced, among others phenomena, by the weld pool dimension and shape. Weld pool shape is important in the development of grain structure and dendrite growth selection process as well as in the development of residual stresses. For these reasons, significant advances have been made in recent years to understand, in greater detail, the dynamics of the heat and fluid flow in the weld and the subsequent development of the pool shape. In numerical simulation of welding processes, there are two different approaches used to model the fusion zone. If the prediction of distortions and residual stresses is the primary objective of the simulation (computational weld mechanics simulation), the phenomenological approach is the most suitable method used to model the fusion zone. Otherwise, when the weld pool shape has to be predicted, the fluid-dynamic equations must be solved at the expense of a significant ‘computational load’ increase. In this work, after a brief description of weld pool characteristics, such two different approaches are described and compared.

Contact Mechanics Analysis of a Rubber Piece on a Smooth Plate

2009 ◽  
Author(s):  
Kyosuke Ono
Keyword(s):  
Contact Mechanics ◽  
Elastic Deformation ◽  
Contact Area ◽  
Large Scale ◽  
Glass Plate ◽  
Applied Pressure ◽  
Small Scale ◽  
Asperity Contact ◽  
The Real ◽  
Parameter Values

In order to elucidate contact and friction characteristics of rubbers, numerical analysis of asperity contact mechanics of a rubber piece with a smooth glass plate was carried out on the basis of an asperity contact model that considers van der Waal’s (vdW) pressure. First, by ignoring vdW pressure and the elastic deformation of the mean height surface, asperity contact characteristics were analyzed using the measured Young’s modulus, and surface parameter values that could yield the measured contact area were estimated. Next, asperity contact characteristics were analyzed by considering the vdW pressure and elastic deformation of a rough sphere that is a model of a large-scale asperity having small-scale asperities. It was found that the actual contact area was similar to the measured contact area; this result could not be obtained without assuming an rms asperity height of ∼0.1 μm for the small-scale asperities. It was also found that the friction coefficient decreased with an increase in the applied pressure in the cases where the friction force is proportional to the real area of contact and to the real internal contact pressure.

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.

scholarly journals Assemblages and Scale in Archaeology

2017 ◽  
Vol 27 (1) ◽  
pp. 127-139 ◽  
Author(s):  
Oliver J.T. Harris
Keyword(s):  
Large Scale ◽  
Multiple Scales ◽  
Daily Life ◽  
Critical Issue ◽  
Small Scale ◽  
Processes Of Change ◽  
Origins Of Agriculture ◽  
The Real ◽  
Historical Processes

The growing interest in assemblages has already opened up a number of important lines of enquiry in archaeology, from the morphogenetic capacities of matter through to a rethinking of the concept of community. In this paper I want to explore how assemblages allow us to reconceptualize the critical issue of scale. Archaeologists have vacillated between expending energy on the ‘great processes’ of change like the evolution of humanity, the colonization of the globe or the origins of agriculture, and focusing on the momentary, fleeting nature of a small-scale ethnographic present. Where archaeologists have attempted to integrate different scales the result has usually been to turn to Annales-influenced or time perspectivism-driven approaches and their fixed, linear and ontologically incompatible layers of history. In contrast, I will use assemblages to examine how we can rethink both the emergence of multiple scales and their role in history, without reducing the differences of the small-scale to an epiphenomenal outcome of larger events, or treating large-scale historical processes as mere reifications of the ‘real’ on-the-ground stuff of daily life. As we will see, this approach also has consequences for the particular kind of reality we accord to large-scale archaeological categories.

scholarly journals Evolution of Large and Small Scale Magnetic Fields in the Sun

1991 ◽  
Vol 130 ◽  
pp. 218-222
Author(s):  
Peter A. Fox ◽  
Michael L. Theobald ◽  
Sabatino Sofia
Keyword(s):  
Numerical Simulation ◽  
Magnetic Fields ◽  
Time Dependence ◽  
Large Scale ◽  
Sunspot Cycle ◽  
Small Scale ◽  
The Sun ◽  
Solar Magnetic Fields ◽  
Magnetic Resistivity ◽  
Statistical Evolution

AbstractThis paper will discuss issues relating to the detailed numerical simulation of solar magnetic fields, those on the small scale which are directly observable on the surface, and those on larger scales whose properties must be deduced indirectly from phenomena such as the sunspot cycle. Results of simulations using the ADISM technique will be presented to demonstrate the importance of the treatment of Alfvén waves, the boundary conditions, and the statistical evolution of small scale convection with magnetic fields. To study the large scale fields and their time dependence, the magnetic resistivity plays an important role; its use will be discussed in the paper.

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