3D Finite Element Simulation of T-Joint Fillet Weld: Effect of Various Welding Sequences on the Residual Stresses and Distortions

In this paper, a finite element simulation, based on abaqus software is presented for analyzing the temperature history and the residual stress states in multipass welds in stainless steel pipe. The uncoupled thermal–mechanical a three-dimensional (3D) model and a two-dimensional (2D) model are developed. The volumetric heat source with double ellipsoidal distribution for front and rear heat source, proposed by Goldak and Akhlaghi, has also been used. Furthermore, a moving heat source has been modeled by abaqus subroutine DFLUX. A user subroutine FILM has also been used to simulate the combined thermal boundary conditions. The results of both a 3D model and a 2D axisymmetric model which are compared with the available experimental measurements show good agreements. Predictions show that the axial and hoop residual stresses in a 3D model and a 2D axisymmetric model have the same distributions in all locations except the starting point of welding. The effects of welding sequences on the thermal and structural analysis are also investigated. Four types of welding sequences for circular welds of pipe have been used and thermal history and axial and hoop residual stresses are compared. Predictions show that for other locations (except the starting point of welding) there are no important differences of axial and hoop residual stresses for welding sequences and they have the same distribution along axial direction.

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Thermomechanical Analysis of Al-7075 to Predict Residual Stresses by Using 3D Finite Element Simulation

Advances in Mechanical Engineering - Lecture Notes in Mechanical Engineering ◽

10.1007/978-981-15-0124-1_26 ◽

2020 ◽

pp. 281-293

Author(s):

Ankit Saxena ◽

Ravindra K. Saxena

Keyword(s):

Finite Element ◽

Residual Stresses ◽

Finite Element Simulation ◽

Thermomechanical Analysis ◽

3D Finite Element ◽

Element Simulation ◽

Al 7075

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3D Finite Element Simulation for Turning of Hardened 45 Steel

Recent Patents on Engineering ◽

10.2174/1872212112666180522082717 ◽

2019 ◽

Vol 13 (2) ◽

pp. 181-188

Author(s):

Meng Liu ◽

Guohe Li ◽

Xueli Zhao ◽

Xiaole Qi ◽

Shanshan Zhao

Keyword(s):

Finite Element ◽

Finite Element Model ◽

Cutting Force ◽

Finite Element Simulation ◽

Orthogonal Experiment ◽

Element Model ◽

3D Finite Element ◽

Element Simulation ◽

Metal Machining ◽

Single Factor Experiment

Background: Finite element simulation has become an important method for the mechanism research of metal machining in recent years. Objective: To study the cutting mechanism of hardened 45 steel (45HRC), and improve the processing efficiency and quality. Methods: A 3D oblique finite element model of traditional turning of hardened 45 steel based on ABAQUS was established in this paper. The feasibility of the finite element model was verified by experiment, and the influence of cutting parameters on cutting force was predicted by single factor experiment and orthogonal experiment based on simulation. Finally, the empirical formula of cutting force was fitted by MATLAB. Besides, a lot of patents on 3D finite element simulation for metal machining were studied. Results: The results show that the 3D oblique finite element model can predict three direction cutting force, the 3D chip shape, and other variables of metal machining and the prediction errors of three direction cutting force are 5%, 9.02%, and 8.56%. The results of single factor experiment and orthogonal experiment are in good agreement with similar research, which shows that the model can meet the needs for engineering application. Besides, the empirical formula and the prediction results of cutting force are helpful for the parameters optimization and tool design. Conclusion: A 3D oblique finite element model of traditional turning of hardened 45 steel is established, based on ABAQUS, and the validation is carried out by comparing with experiment.

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