Figure 14 Comparison of the experimental distortions with those
predicted by the FE models considering and not the plates interaction:
A, along the path at y = 248 mm and z = 0 mm and B, along
the path at x = 125 mm and z = 0 mm.
As aforementioned, in order to appreciate the effects provided by the
modelling of the plates interaction during the welding process, the
predicted residual stresses and distortions have been compared with
those provided by the simulation performed by deactivating the plates
interaction (Figures 13 and 14).
According to Figure 13A, as expected, it can be noticed that the
longitudinal residual stresses distribution seems to be unaffected by
the plates interaction. As matter of the fact, plates have not been
constrained along the longitudinal direction. Contrary, the plates
interaction affects the transversal residual stresses distributions,
because of the plates rotation during the welding process. Residual
stresses appear to be slightly higher (Figure 13B) for the model that
does not consider the plates interaction and they are expected to
increase for longer plates, because of their rotation.
If the effects of the plates interaction on residual stresses
distribution may be considered negligible for the selected test case, a
similar consideration cannot be done in terms of distortions
distribution. According to Figure 14, the predicted distortions
distribution appears to be sensibly higher and far from the experimental
data for the FE model that does not consider the plates interaction. As
a result, the plates interaction plays a key-role in the modelling of
the welding process induced distortion.
5. conclusions
This paper presents a novel numerical model, based on the Finite Element
method, for the simulation of a welding process aimed to make a
two-passes V-groove butt weld joint. In order to evaluate the residual
stresses, a 3D non-linear thermo-mechanical analysis has been carried
out. The thermo-mechanical response of the joint has been simulated by
using an uncoupled approach. Specifically, the “element birth and
death” technique has been used to simulate the welding filler during
the welding process. The originality of the proposed technique has to be
found in the simulation of the interaction occurring between the two
plates during the welding process, never considered in literature when
the problem is faced through a symmetrical approach. As a result, it was
possible to predict more accurately the residual stresses affecting the
joint, caused by the thermal distortions which lead the plates to
rotate. The proposed modelling technique appears to be fundamental for
long plates, since the plates interaction becomes not negligible as the
plate length increases. Specifically, in order to save the computational
costs, only a plate and half seam have been modelled. As a result, in
order to simulate the plates interaction, a row of finite elements has
been placed along the left side of the longitudinal symmetry plane. This
approach allows predicting the residual stresses also for long joined
plates, which require a higher number of nodes and elements and,
consequently, a higher time analysis. A surface to surface contact
algorithm has been considered between the half seam and the finite
elements row.
Moreover, differently from the literature, the heat amount is supplied
to the finite elements as a volumetric generation of the internal
energy, allowing overcoming the time-consuming calibration phase
required by the Goldak’s model, commonly adopted in literature.
The reliability of the FE model has been shown by assessing the
predicted results, in terms of temperatures distribution and joint
distortion, against the results provided by an experimental test.
Temperatures distribution has been measured during the welding process
by using six thermocouples placed at different locations nearby the weld
bead; welding distortions were measured by means of a Coordinate
Measuring Machine. A good agreement has been found between numerical and
experimental results, showing the effectiveness of the proposed FE
modelling technique.
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