Deformation Analysis for Welding Assembly Processes of Automobile Panels

2010 ◽  
Vol 118-120 ◽  
pp. 70-74
Author(s):  
Yu Liu ◽  
Jian Xin Liu ◽  
Shu Yi Yan ◽  
Zhi Min Wang ◽  
Bing Zhang
Keyword(s):  
Numerical Simulation ◽  
Welding Process ◽  
Coupling Method ◽  
Welding Distortion ◽  
Deformation Analysis ◽  
Assembly Quality ◽  
Automobile Body ◽  
Dimensional Deviation ◽  
Assembly Deviation

Welding process of automobile panels is a key process in the manufacturing of automobile body and its quality directly impact on the appearance and quality of automobile. The causes of dimensional deviation of welded assembly could be workpieces variation, assembly tooling variation, and welding distortion. As a major source of assembly deviation, dimensional variations of workpieces have important effects on the assembly quality of automobile body. In this paper, pre-stressing was used to reflect the workpieces’ variation and the node coupling method was used in the numerical simulation to predict the deformation of assembly caused by the welding process of automobile panels. And further the computation results were listed and compared with the measured ones.

Using of Welding Virtual Numerical Simulation as the Technical Support for Industry

2016 ◽  
Vol 1138 ◽  
pp. 49-55
Author(s):  
Marek Slováček ◽  
Josef Tejc ◽  
Mojmír Vaněk
Keyword(s):  
Numerical Simulation ◽  
Numerical Simulations ◽  
Welded Joints ◽  
Welding Process ◽  
Austenitic Steels ◽  
Welding Parameters ◽  
Efficient Production ◽  
Weld Joints ◽  
Mechanical Properties Prediction

Welding as a modern, highly efficient production technology found its position in almost all industries. At the same time the demands on the quality of the welded joints have been constantly growing in all production areas. Great demand on the quality of the welded joints consequently causes more experimental or prototype – so called – validation joints that take place before the welding of final construction. These experiments, prototypes aim at – for instance – defining the appropriate welding technology, material, pre-heating, welding parameters, clamping condition and optimizing the welding process. Naturally, these experiments and prototypes make production more expensive. Numerical simulations of welding – in the area of production preparation as well as of production proper – have been frequently used recently. Numerical simulations supported by experimental measurements can simulate the actual welding process very close to reality. The new material models for hardness and mechanical properties prediction based on numerical simulation solution will be introduced.The paper covers some typical welding cases from energy industrial sector. The homogenous and heterogeneous weld joints from modern energy Cr-Mo-Ni-V steels (including modern austenitic steels) were done as prototype welding. The numerical simulation of these weld joints including post weld heat treatment process were done and welding technologies were optimised based on the numerical simulation results. The calculated hardness was compared with real measurements. During project the complete material properties which are needed for numerical simulation were measured. Simplify numerical lifetime prediction of weld joints including results from numerical welding analyse (as residual stresses and plastic deformation) were done.

Numerical Simulation of Welding Distortion Using Shrinkage Force Approach and Application

2010 ◽  
Vol 129-131 ◽  
pp. 867-871 ◽  
Author(s):  
Yao Hui Lu ◽  
Ping Bo Wu ◽  
Jing Zeng ◽  
Xing Wen Wu
Keyword(s):  
Numerical Simulation ◽  
Welding Distortion ◽  
Railway Vehicle ◽  
Welding Deformation ◽  
Element Analysis ◽  
Force Method ◽  
The Finite Element Analysis ◽  
Numerical Simulation Methods ◽  
Shrinkage Force

The control of welding distortion during assembling process is very important. Using numerical simulation methods to obtain the welding distortion is an effective way to control the quality of welding. At first, taking the bead-on-plate welding as an example, the predictions of welding distortion were made using the shrinkage force method and the thermo-elastic-plastic method for comparison. It was concluded from the comparison that the simulation results by using the two methods are consistent. Therefore, the shrinkage force method can be applied to prediction of structural welding distortion in engineering. Based on the theory of welding shrinking force, welding deformation was predicted for the bogie side frame of railway vehicle. According to all the deformation results from the finite element analysis, the welding deformation of the bogie side frame was lager than the tolerance of quality and in reasonable agreement with the experimentally determined distortion values from literature. The work in this paper indicated that the shrinkage force method was effective to predict the welding deformation and to control the welding quality in large complex structures, such as the bogie frame of railway vehicle.

Simulation on temperature fields and phase transformation of 316L stainless steel tubes during Orbital – TIG auto welding process

2021 ◽  
Vol 95 ◽  
pp. 2-10
Author(s):  
Manh Ngo Huu ◽  
Keyword(s):  
Numerical Simulation ◽  
Stainless Steel ◽  
Phase Transformation ◽  
316L Stainless Steel ◽  
Welding Process ◽  
Temperature Fields ◽  
Heat Distribution ◽  
Steel Tubes ◽  
Steel Pipes

Orbital - TIG (OT) auto welding process was applied for the weld connection of the fixed pipe lines. The heat distribution of the OT welding has influenced phase transformation and quality of the weld. In this paper, the temperature fields and phase transformation of 316L stainless steel pipes have been simulated during OT auto welding process. The numerical simulation has been used and supported by the JMATPRO 7.0 and SYSWELD softwares.

Numerical Simulation of Welding Distortion under Different Sequences

2011 ◽  
Vol 328-330 ◽  
pp. 638-641 ◽  
Author(s):  
Yang Liu ◽  
Dong Po Wang ◽  
Hai Zhang
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Welding Process ◽  
Welding Distortion ◽  
Finite Element Software ◽  
Reasonable Number ◽  
Welding Sequences

Finite element software ANSYS was used to study the influence of welding sequences on the distortion generated in the welding process of a Q345 plate with V-groove. The simulation of the welding process consists of sequentially coupled thermal and structural analyses using element birth and death technique. The results show that the backstep welding makes the distortion decrease. But back welding with too many steps makes the distortion increase. For a structure, the most reasonable number of steps can be found.

scholarly journals THE OPTIMIZATION OF CLAMPING METHOD IN REDUCING WELDING DISTORTION OF LOW CARBON STEEL

2016 ◽  
Vol 20 (2) ◽  
Author(s):  
Heri Wibowo
Keyword(s):  
Carbon Steel ◽  
Test Specimen ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Bending Test ◽  
Angular Distortion ◽  
Welding Distortion ◽  
Low Carbon ◽  
Optimal Point

This study aimed to reduce levels of distortion welding through Clamping method so that the parameters of the most optimal Clamping against distortion and cracking resistance would be recognized. The method was applied to the workpiece Clamping before welding by 5 methods that include: without Clamping, 2 points Clamping, 4 points Clamping, 6 points Clamping and 4 points + fulcrum campling. The tests carried out on the workpiece welding include: distortions test (angles, curves and twisting) and shrinkage tests (transverse and longitudinal) and bending test for crack resistance. The results show that Clamping method is capable on reducing the level of distortion due to the welding process. Four Clamping method is considered the most optimal point in reducing the level of distortion with 2.2 angular distortion, 3.2 mm bending distortion, and without twist distortion. Bending testing shows that Clamping method does not degrade the quality of welded joints based on the acceptance of all bending test specimen

scholarly journals Directional hyper-reduced model for evaluation of residual welding stresses in code_aster

2018 ◽  
Author(s):  
Tuan Dinh-Trong ◽  
David Ryckelynck ◽  
Mickaël Abbas ◽  
Sofiane Hendili
Keyword(s):  
Numerical Simulation ◽  
Heat Source ◽  
Residual Stresses ◽  
Boundary Conditions ◽  
Welding Process ◽  
Computation Time ◽  
Reduced Model ◽  
Residual Welding ◽  
Parametric Studies

The welding process produces strains and residual stresses that must be taken into account to evaluate the final quality of the assembly. For that, the simulation of the process by a thermomechanical computation is very widely used. Numerical simulation uses many parameters (materials, heat source, boundary conditions) whose effects must be studied. But as the compuation becoming very expensive, massive parametric studies quickly become unusable. To reduce the computation time, we propose an approach based on the spatial and temporal similarity of thermal results, by a method of hyper-reduction on a slice of the domain.

Multifactor mathematical model of criticality of welding process of products from aluminum- magnesium alloys

2020 ◽  
pp. 12-18
Author(s):  
F.A. Urazbahtin ◽  
A.YU. Urazbahtina
Keyword(s):  
Mathematical Model ◽  
Magnesium Alloy ◽  
Magnesium Alloys ◽  
Welding Process ◽  
Welding Equipment ◽  
Equipment Operation ◽  
Aluminum Magnesium Alloys ◽  
Aluminum Magnesium Alloy ◽  
Welding Materials

A multifactor mathematical model of the welding process of products from aluminum-magnesium alloys, consisting of 71 indicators that assess the quality of the weld, the welding process, costs, equipment operation and quality of the welded material. The model can be used to control and optimize the welding process of products from aluminum-magnesium alloys. Keywords welding, products, aluminum-magnesium alloy, indicators, process parameters, welding equipment, welding materials, electrode sharpening, lining [email protected]

Numerical Simulation on Mold Electromagnetic Eccentric Stirring and Central Segregation of Round Bloom

2013 ◽  
Vol 652-654 ◽  
pp. 2450-2454
Author(s):  
Zhi Hong Zhang ◽  
Guo Guang Cheng
Keyword(s):  
Numerical Simulation ◽  
Mathematical Model ◽  
Electromagnetic Stirring ◽  
Center Line ◽  
Central Segregation

The paper describes multi-section round bloom casting using external MEMS, equipped with max section D600mm and min D280mm mold, the center line of D280mm mold not coincident with the axis of stirrer coils. it is exist eccentric electromagnetic stirring of mold which section less than max D600mm, a mathematical model of MEMS has been established, the index of central segregation of D280mm macrostructure had decreased less than 1.12 by optimized parameters of electromagnetic stirring and SEN immerse depth, in the end, the quality of round bloom had improved.

scholarly journals Geometry and Distortion Prediction of Multiple Layers for Wire Arc Additive Manufacturing with Artificial Neural Networks

2021 ◽  
Vol 11 (10) ◽  
pp. 4694
Author(s):  
Christian Wacker ◽  
Markus Köhler ◽  
Martin David ◽  
Franziska Aschersleben ◽  
Felix Gabriel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Welding Process ◽  
High Energy ◽  
Welding Distortion ◽  
Direct Energy Deposition ◽  
Direct Energy ◽  
Industrial Use ◽  
Artificial Neural ◽  
Artificial Neural Network Ann ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) is a direct energy deposition (DED) process with high deposition rates, but deformation and distortion can occur due to the high energy input and resulting strains. Despite great efforts, the prediction of distortion and resulting geometry in additive manufacturing processes using WAAM remains challenging. In this work, an artificial neural network (ANN) is established to predict welding distortion and geometric accuracy for multilayer WAAM structures. For demonstration purposes, the ANN creation process is presented on a smaller scale for multilayer beads on plate welds on a thin substrate sheet. Multiple concepts for the creation of ANNs and the handling of outliers are developed, implemented, and compared. Good results have been achieved by applying an enhanced ANN using deformation and geometry from the previously deposited layer. With further adaptions to this method, a prediction of additive welded structures, geometries, and shapes in defined segments is conceivable, which would enable a multitude of applications for ANNs in the WAAM-Process, especially for applications closer to industrial use cases. It would be feasible to use them as preparatory measures for multi-segmented structures as well as an application during the welding process to continuously adapt parameters for a higher resulting component quality.

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