Numerical Simulation of Welding for Box Beam Structure on Bogie of High Speed Train

2011 ◽  
Vol 399-401 ◽  
pp. 1816-1819
Author(s):  
Huan Jun Liu ◽  
Jian Xin Liu ◽  
Hui Chen ◽  
Hua Ji ◽  
Zhi Yi Zhang
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
High Speed ◽  
Weathering Steel ◽  
Beam Structure ◽  
Element Analysis ◽  
Box Beam ◽  
Welding Sequence ◽  
Side Beam ◽  
Welding Sequences

In this paper a typical box beam structure on certain high speed power car was taken as study object, Based on the finite element analysis software SYSWELD, established the material parameters database for SMA490BW weathering steel, and performed the numerical simulation for the welding of typical box beam structure of side beam of high speed bogie, comparison between the simulation results and that of experiment test verified the existing welding procedures. For the purpose of studying the influence of welding sequence on the residual stress and providing theoretical support for actual production, the residual stress under different welding sequences was investigated then.

Research on the Effects of Welding Sequence on Welding Residual Stress of High-Speed Train Based on SYSWELD

2011 ◽  
Vol 399-401 ◽  
pp. 1806-1811
Author(s):  
Yong Hong Chen ◽  
Peng Chen ◽  
Ai Qin Tian
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
High Speed ◽  
Element Model ◽  
Welding Residual Stress ◽  
High Speed Train ◽  
Distribution Law ◽  
Element Analysis ◽  
Welding Sequence ◽  
Maximum Residual Stress

The finite element model of the roof of aluminum high-speed train was established, double ellipsoid heat source was employed, and heat elastic-plastic theory was used to simulate welding residual stress of the component under different welding sequence based on the finite element analysis software SYSWELD. The distribution law of welding residual stress was obtained. And the effects of the welding sequence on the value and distribution of residual stress was analyzed. The numerical results showed that the simulation data agree well with experimental test data. The maximum residual stress appears in the weld seam and nearby. The residual stress value decreases far away from the welding center. Welding sequence has a significant impact on the final welding residual stress when welding the roof of aluminum body. The side whose residual stress needs to be controlled should be welded first.

Influences of Welding Sequence on Residual Stress of Plate Butt Welding

2010 ◽  
Vol 26-28 ◽  
pp. 568-572
Author(s):  
Peng Ji ◽  
Qing Hua Dai ◽  
Chen Bo Yin ◽  
Di Sheng Yi ◽  
Bin Wang ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Butt Welding ◽  
Welding Sequence ◽  
Longitudinal Residual Stress ◽  
Welding Sequences ◽  
Large Side

For the plate butt welding of the same materials with different geometry structures, the numerical simulation was adopted to analyze the influences of welding sequence on transverse and longitudinal residual stress in the process of multi-layer and multi-pass welding. The results show that when welding from the small geometric side to the large side, the peak values of transverse and longitudinal residual stress are min along the bottom or top axis of the weld. And the welding sequences of the foremost welds have little effects on transverse and longitudinal residual stress along the bottom or top axis of the weld.

Numerical Simulation for Residual Stress and Deformation of Surface Welding on Membrane Water-Wall

2014 ◽  
Vol 490-491 ◽  
pp. 594-599
Author(s):  
Fan Ling Meng ◽  
Ai Guo Liu
Keyword(s):  
Residual Stress ◽  
Great Influence ◽  
Residual Deformation ◽  
Welding Residual Stress ◽  
Finite Element Software ◽  
Welding Sequence ◽  
Surface Welding ◽  
Stress And Deformation ◽  
Welding Sequences ◽  
Residual Stress And Deformation

Automatic MIG was adopted to weld Inconel 625 alloy on 20 G Membrane Waterwall, which can improve the capacities of high temperature corrosion resistance and wear resistance. To study the influence of Membrane Waterwall surface welding sequences on residual stress and residual deformation, this paper utilized finite element software ABAQUS and segmented moving heat source model to simulate the sequence welding, balanced welding from the middle to sides, balanced welding from sides to the middle, balanced skip welding from middle to sides and balanced skip welding from sides to the middle and studied their residual stresses and deformations. The simulation results indicated that there was a great influence of welding sequences on the residual stress and deformation. The optimal welding sequence was balanced skip welding from middle to sides and balanced skip welding from sides to the middle, which could change the stress distribution, decrease the welding residual stress by 17%, realize the even deformation of the whole welding section and decrease the bending deformation by 50%.

Numerical Study of Welding Sequence on the Residual Stress Field in a Thick-Walled Tee Joint

2011 ◽  
Vol 219-220 ◽  
pp. 1211-1214
Author(s):  
Wei Jiang
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Numerical Study ◽  
Three Dimensional ◽  
Element Model ◽  
Residual Stress Field ◽  
Factors Affecting ◽  
Welding Sequence ◽  
Welding Sequences ◽  
Three Dimensional Finite Element

Finite element simulation is an efficient method for studying factors affecting weld-induced residual stress distributions. In this paper, a validated three-dimensional finite element model consisting of sequentially coupled thermal and structural analyses was developed. Three possible symmetrical welding sequences, i.e. one-welder, two-welder and four-welder sequence, which were perceived to generate the least distortion in actual welding circumstances, were proposed and their influences on the residual stress fields in a thick-walled tee joint were investigated. Appropriate conclusions and recommendations regarding welding sequences are presented.

Numerical Simulation of Residual Stress Field Induced by Water-Jet Cavitation Peening

2013 ◽  
Vol 345 ◽  
pp. 312-315 ◽  
Author(s):  
Bing Han ◽  
Yan Hua Wang ◽  
Chang Liang Xu
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Stress Field ◽  
New Technology ◽  
Diffraction Method ◽  
Spring Steel ◽  
Water Jet ◽  
Material Surface ◽  
Residual Stress Field ◽  
Element Analysis

Water-jet cavitation peening is a new technology for surface modification of metallic materials. Compress residual stress layer is induced by impact wave pressure in the submerged cavitating jets processing. Based on ANSYS/LS-DYNA finite element analysis software, residual stress field in the SAE1070 spring steel material surface induced by cavitate-jet water peening process is simulated, the magnitude and variation rules of the residual stress along the layer depth under different conditions is obtained. In order to verify the correctness of the numerical simulation, the size and distribution of residual stress by the X-ray diffraction method. The results show that the numerical simulation and experimental results are well consistent.

Finite Element Analysis and Optimization of Structure for Large Blanking Machine Equipment during High-Speed Blanking

2011 ◽  
Vol 697-698 ◽  
pp. 176-181
Author(s):  
Shu Bo Xu ◽  
K.K. Sun ◽  
Cai Nian Jing ◽  
Guo Cheng Ren
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Optimal Design ◽  
High Speed ◽  
Dynamic Performance ◽  
Design Stage ◽  
Beam Structure ◽  
Element Analysis ◽  
Blanking Process ◽  
Dynamic Performance Analysis

This paper reviews the background and significance to investigate the high-speed speed blanking process modeling simulation and optimization of large blanking machine equipment for CNC uncoiling, leveling and shearing line. And a powerful tool has been providing to of heavy machinery optimal design specifications. The finite element model of beam structure has been established by using a three-dimensional modeling software UG NX4.0 CAD and finite element analysis software ANSYS. Then the static and dynamic characteristics results of the whole beam structure have been simulated. On the basis of analysis results, the optimal static and dynamic performance of square cross-section of the beam structure has been obtained. Drawings at the design stage of large blanking machine equipment for NC uncoiling, leveling and shearing line, the use of finite element theory and modal analysis theory, the structure of the blanking machine static and dynamic performance analysis and prediction using optimal design method for optimization, the new machine to improve job performance, improve processing accuracy, shorten the development cycle and enhance the competitiveness of products is very important.

Numerical Simulation of Welding Sequence Effect on Temperature Distribution, Residual Stresses and Distortions of T-Joint Fillet Welds

2011 ◽  
Vol 264-265 ◽  
pp. 254-259 ◽  
Author(s):  
N. Syahroni ◽  
M.I.P. Hidayat
Keyword(s):  
Numerical Simulation ◽  
Temperature Distribution ◽  
Residual Stresses ◽  
Angular Distortion ◽  
Element Simulation ◽  
Welding Sequence ◽  
And Performance ◽  
Welding Sequences ◽  
Two Sides ◽  
Contrary Direction

Welding sequence is one important factor which affects the residual stresses and distortions produced during welding, thus determines the welding quality and performance. In this paper, 3D numerical simulation of temperature distribution, residual stresses and distortions of the T-joint fillet weld with respect to the variation of welding sequence is presented. The finite element simulation involved thermo-mechanical analyses. Four welding sequences (WS) considered are one direction welding (WS-1), contrary direction welding (WS-2), welding from centre of one side (WS-3) and welding from centres of two sides (WS-4). The simulation results revealed that peak temperature achieved in the welding was greatly affected by the welding sequence and residual stress and angular distortion produced cannot both hold in minimum for a WS. The smallest residual stresses and the smallest angular distortions are related respectively to WS-2 and WS-4. The distributions of temperature, longitudinal and transverse residual stresses as well as angular distortions were also presented.

Influence of the Welding Sequence on Residual Stresses in Laser Welded T-Joints of an Airframe Aluminium Alloy

2008 ◽  
Vol 571-572 ◽  
pp. 375-380 ◽  
Author(s):  
Winulf Machold ◽  
Peter Staron ◽  
Funda S. Bayraktar ◽  
Stefan Riekehr ◽  
Mustafa Koçak ◽  
...  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Welding Process ◽  
Base Plate ◽  
Stress Fields ◽  
Stress Concentrations ◽  
T Joints ◽  
Element Simulation ◽  
Welding Sequence ◽  
Welding Sequences

The effect of different welding sequences between a 4.5 mm thick AA 6156 T6 base plate and a 2 mm thick AA 6013 T6 clip – resembling a skin-clip joint of an airframe – using a 3.3 kW Nd:YAG laser is investigated. Under cyclic loading the breakdown of such T-joints happens at one end of the clip, which is due to local residual stress concentrations. Recent measurements indicated that tensile stresses could be lower at the run-in than at the run-out locations. For a deeper investigation of this effect sheets with different welding sequences were produced. One welding sequence was made with two starting points in the centre, and a second with starting points at the clip ends. Temperature measurements were made using thermocouples to verify the heat conditions for a finite element simulation of the welding process, which is used for predictions of the residual stress distribution. Actual values of the residual stress fields were determined by neutron diffraction. The influences of the welding sequence on the measured temperatures and the residual stresses are discussed.

Optimization of the welding sequence and direction for the side beam of a bogie frame based on the discrete particle swarm algorithm

2016 ◽  
Vol 232 (8) ◽  
pp. 1423-1435 ◽  
Author(s):  
Qing Shao ◽  
Tao Xu ◽  
Tatsuo Yoshino ◽  
Nan Song ◽  
Zhenglei Yu
Keyword(s):  
High Speed ◽  
Particle Swarm ◽  
Residual Deformation ◽  
Computational Time ◽  
Particle Swarm Algorithm ◽  
Optimal Result ◽  
Bogie Frame ◽  
Discrete Particle ◽  
Welding Sequence ◽  
Side Beam

For any large weldment with many welding seams, the welding sequence and direction have a strong influence on the assembly and service performance, especially for the side beam of the bogie frame of a high-speed rail passenger car (CHR3; CRRC, Changchun, China). Because different combinations of the welding sequence and direction greatly increase the computational time and research costs, a three-dimensional finite element approach was developed to investigate the optimal welding sequence and direction. Then, a surrogate model was established by design of experiment and used the concepts of a pointer and stack. Finally, the welding sequence and direction were optimized by the discrete particle swarm optimization algorithm. The max residual deformation and stress of the optimal result were −3.92 mm and 212.56 MPa, respectively, which is approximately 22% and 38% lower than the traditional enterprise plan, respectively. Furthermore, a weighted form of the residual deformation and stress was proposed to the end of optimum comprehensive effect, and the result also had 11% and 28% reduction, respectively. The simulation result of the optimal plans well reproduced the theoretical distribution results of the residual deformation and stress. It is proven that the optimal result can improve the welding quality and process of the side beam weldment in production.

scholarly journals Mechanism of Blunt Punching Tools’ Influence on Deformation and Residual Stress Distribution

Metals ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 2029
Author(s):  
Wei Wang ◽  
Xiang Fang ◽  
Xuanguo Wang ◽  
Michel Andrieux ◽  
Vincent Ji
Keyword(s):  
Numerical Simulation ◽  
Residual Stress ◽  
Magnetic Properties ◽  
High Efficiency ◽  
Local Deformation ◽  
Cutting Edge ◽  
Tensile Residual Stress ◽  
Iron Core ◽  
Machining Accuracy ◽  
Element Analysis

Punching is the main manufacturing process with high efficiency and machining accuracy used to produce the iron cores of motors. However, it usually introduces residual stress at the cutting edge and affects the magnetic properties of the iron core. Further studies show that the tensile residual stress (TRS) has a negligible effect on the magnetic properties, compared with the compressive stress. The blunt punch tools cause local TRS and the formation of local large plastic deformation (PD) at the cutting edge as the cost. The PD has a more serious effect on the magnetic properties of materials than TRS. Therefore, this study mainly focused on local deformation distribution and the associated microstructure evolution using EBSD (Electron Backscatter Diffraction) and finite element analysis; and the formation mechanism of tensile residual stress during the punching process at the cutting edge of a non-oriented silicon steel after punching with blunt tools, by using nanoindentation and a numerical simulation. The experimental results showed the existence of a specific bending area, a highly deformed area and a large burr at the cutting edge. These direct observations were confirmed with those obtained by the simulation model. Furthermore, the tensile residual stress on the surface was verified through nanoindentation tests and by a numerical simulation. The results indicate also that the formation of a tensile residual stress zone depends especially on the bending area formed during punching with blunt tools.

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