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PVP2004-2653
A. Ezeilo
TWI, Granta Park
Cambridge CB 1 6AL, UK
Emaih Andy.Ezeilo @twi.co.uk
ABSTRACT
Virtual fabrication technology (VFT) weld modeling
software has been mainly used in thick-structure welding
simulation. Recently both U. S. and European shipyards have
shown strong interests in using the software to predict and
control welding distortion of thin-plate ship panels. It is more
complicated to simulate the welding of thin structures than thick
structures because buckling distortion often occurs during the
welding of thin structures. To evaluate the effectiveness of VFT
for predicting distortion in thin structures, a bead-on-plate
specimen, a butt joint of two large plates, and a long T stiffener
were analyzed with VFT welding modeling software. By
comparing the predicted distortions with those obtained by
measurement, it was found that VFT can accurately predict
welding-induced distortions of thin structures. Sensitivity
studies show that pre-deformation induced by upstream
fabrication processes and heat input are important factors
influencing predicted distortions. Both distortion trends and
magnitudes for thin structures are influenced by predeformation and heat input.
INTRODUCTION
Lightweight structures are being increasingly used in recent
years in both U. S. shipyards and European shipyards. From
1990 to 2000, the production ratio of thin steel (10ram or less)
to plate structures for certain specific vessels has risen to over
90% by weight [1]. Severe distortions have been observed in
the building of large thin ship panels. To understand the
distortion mechanism and propose suitable methods to control
distortion, shipbuilders urgently need a distortion prediction
tool which is able to be used to assist the building of the thin
ship panels.
Many researchers [2-6] have tried to develop modeling
methodologies to simulate the welding process, but the
modeling techniques that have been developed have often been
too complex, inaccurate, or too labor intensive to be applied
industrially. Although significant progress has been made in
finite-element modeling of welding processes in recent years,
many of the modeling techniques are still far short of being used
99
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WELD
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Local Weld Residual Stress Analysis Procedure
This analysis procedure is mainly used to calculate weld
residual stress on the local level of a welded structure. As
shown in Fig. 1, 2D cross section models (generalized plane
strain or axis-symmetric models) are normally used for the local
weld residual stress analysis. VFT-DFLUX subroutine is
recommended for accurate modeling of heat input and
prediction of temperature field and history. To effectively use
this DFLUX subroutine, a FEA model should be generated
based upon the weld cross section profile or at least the closest
estimation of a weld cross section area. Tacks welds should be
included in FEA models. In some situations, surface contacts
and proper boundary conditions may be used to simulate
constraint from the welding fixture. The Global-to-local
modeling procedure could be used if a significant 3D effect
exists.
Distortions
Structural Model
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1.50
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, . has been,discussed in detail in Ref. 11.
Fig. 8 Distortion comparisons oetween preaicuon a n a experiment
103
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Note that the analysis of the 3D shell model took much less
CPU time than that of the 3D solid model and the 3D shell
model was much easier to create. For a large and complex
structure, this work suggests that it will be beneficial to choose
a 3D shell model for predicting welding-induced distortions.
1500C
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Unit: mrn
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Magnification = 10
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104
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~hape
Fig. 12 Mapping Pre-deformation to the Weld Model
It should be pointed out that tack-weld induced distortions
can be predicted using VFT. This way, users don't need to map
the pre-deformed shape to the weld model. The disadvantage is
that the distortion before tack welding, i.e. the initial plate
shape, may also need to be included in the weld model.
A pre-deformed shape can have a great impact on the
resistance of the structure to buckling distortion. It reduces the
buckling strength of the structure. If buckling happens, the predeformed shape will determine the distortion direction.
Therefore, if the simulation does not include the predeformation, the predicted distortions could be in the opposite
direction to the actual distortions. As such the predicted
distortion magnitude could be smaller than the experimental
results.
105
Boundary conditions:
Corner 1 & 2: x=y=z=O
Corner 3: x=y=O
rner 4: y=O
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Corner 1
.
Corner 4
TY
z
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Dimensions: 2286x127x6.35
Materials: DH-36
Welding process: MIG,
Weld: double-side 6.35 fillet
Fig. 15 A double T-fillet Model
.L
SUMMARY
This paper has reviewed the overall modeling procedures
available in VFT weld simulation software. The moving arc
modeling procedure was used to analyze the welding of a beadon-plate specimen, a butt-joint, and a Tee stiffener. Predeformation before welding, heat input, and weld size greatly
contribute to buckling distortions. It is therefore suggested that,
they should be included in any simulation exercise to accurately
predict welding-induced distortions, particularly of thin
structures. The T-stiffener analysis shows that VFT software is
suitable for predicting distortion of large ship panels. More
results will be published in the near future.
REFERENCES
1. Huang, T.D., Dong, P., DeCan, L., and Harwig, D.,
"Residual Stress and Distortions in Lightweight Ship Panel
Structures,"
TRW
Technical Review
Journal,
Spring/Summer, 2003.
. Masubuchi, K., "Prediction and control of residual stress
and distortion in welded structures," Welding Research
Abroad, 1997, 43, June-July, 1997, pp. 2-16.
3. Goldak, J., "Progress and Pacing Trends In Computational
Weld
Mechanics,"
Proceedings of International
Conference on Computer Engineering and Science, 1998.
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106
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4.
17. Brust, E W., Scott, EM, and Yang, Y.E, "Weld Residual
Stress and Crack Growth in Bimetallic Pipe Welds,"
Proceeding of 17th International Conference on Structural
Mechanics in Reactor Technology (SMIRT 17), Prague,
August 17-22, 2003.
18. Yang, Y. E, Brust, E W., Cao, Z. Dong, Y., and Nanjundan,
A., ''Welding-induced distortion control techniques in
heavy industries," Proceedings of the 6th International
Conference on Trends in Welding Research, Pine Mountain,
Georgia; April 15-19, 2002, pp.844-849.
19. Yang, Y. E, Chen, X. L., Dong, E, Varol, I. Cao, Z., and
Hong, J. K., "Experimental and Finite element Study of
Laser Cutting Induced Distortion in a Production
Environment," International Conference on Computer
Engineering and Science, 31 July-2 August, 2002, Reno,
NV, USA.
20. Yang, Y. P., Brust, F. W., and Kennedy, J. C., "Lump-Pass
Welding Simulation Technology Development for
Shipbuilding Applications," Proceeding of ASME Pressure
Vessels and Piping Conference, 4-8 August, 2002,
Vancouver, British Columbia, Canada.
21. Masubuchi, K., "Analysis of Welded Structures,"
Pergamon Press, Oxford, 1980, pp. 235, 331.
22. Cao, Z., P. Dong, and Brust, F. W., "A Highly Efficient
Heat-Flow Solution Procedure", Proceedings of 1CES'98,
October 7 - 9, Atlanta, 1998.
23. Y. P. Yang and P. Dong, "Prediction and Control of
Buckling Distortion in Thin-Wall Welded Structure", 80th
American Welding Society Annual Meeting, April 12-15,
St. Louis, MO, 1999.
ACKNOWLEDGMENTS
The authors would like to acknowledge Tower Automotive
for supporting this study. Adam Fisher, Robert Broman and Raj
Thakkar participated in the experimental work of the bead-onplate welding test. BAE Systems Naval Ships and the
University of Newcastle provided the measurement results of
the butt joint welding test. TWI coordinated the study of the
butt joint.
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