Residual Notch Stress Intensity Factors in Welded Joints Evaluated by 3D Numerical Simulations of Arc Welding Processes

Approaches based on calculating Residual Notch Stress Intensity Factors (R-NSIFs) assume the weld toe to be a sharp V-notch that gives rise to a residual singular stress distribution close to the weld toe. Once R-NSIFs are determined, they might be included in local fatigue criteria for the structural strength assessment of welded joints based on NSIFs due to external cyclic loading. However, the numerical calculation of R-NSIFs through finite element (FE) simulations of the welding process requires extremely refined meshes to properly capture the residual stress singularity. In this context, the Peak Stress Method (PSM) has recently been adopted to estimate R-NSIFs due to residual stresses by means of coarse meshes of 2D 4-node plane or 3D 8-node brick elements. The aim of this work is to investigate the applicability of the PSM to estimate R-NSIFs in a butt-welded joint using coarse meshes of 3D 10-node tetra elements. The R-NSIF distribution at the weld toe line is estimated by applying the PSM to coarse meshes of 3D 10-node tetra elements, and the results are in agreement with those obtained using 3D 8-node brick elements. Accordingly, the PSM based on tetra elements further enhances the rapid estimation of R-NSIFs using coarse meshes and could be effective in analyzing complex 3D joint geometries.

Numerical Estimation of Notch Stress Intensity Factors of Sharp V-Notches

In the present work a simple and efficient least squares method is implemented for accurate estimation of notch stress intensity factors (NSIFs) of sharp V-notches. Finite element (FE) stress components near a notch tip is used in the present method for determining the NSIFs. Pure mode I and mixed mode (I/II) examples are considered for numerical investigations. The mixed mode stress components are disintegrated into opening mode and shear mode stress components to separate out the mode I and mode II singularities. Thereafter, least squares method is implemented to calculate mixed mode NSIFs. The present method is easy to incorporate in existing standard finite element codes. The results obtained by the present method are found to be in good agreement with the published data.