Finite Element Analysis of Residual Welding Stresses and Deformation for a 5A06 Aluminum Alloy Plate
TL;DR: In this paper, the residual stresses and deformation in terms of the thermoelastoplastic theory were simulated with the finite element method using ANSYS 13.0 software for a 5A06 aluminum alloy plate after welding.
Abstract: The residual stresses and deformation, in terms of the thermoelastoplastic theory, were simulated with the finite element method using ANSYS 13.0 software for a 5A06 aluminum alloy plate after welding. The butt joint thickness of the plate was 6 mm. A 3D thermomechanical model of the plate was constructed. The dimensions and distribution of residual stresses in the welded structure should be analyzed after simulation. Appropriate welding technologies were chosen to control welding residual stresses and deformation. The efficient production of an aluminum alloy for the welded structures will be provided.
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TL;DR: In this paper , a simulation method of residual stress in aluminum alloy welds, based on computer simulation technology, combines finite element technology to construct a simulation system of residual stresses in aluminum Alloy welding seam.
5 citations
19 Feb 2021
TL;DR: In this article, the authors investigated the evolution mechanisms of transient strain and residual stress distribution in laser welding of Al 6061, considering that these originate from non-uniform temperature distribution and are intensified further by the unbalanced procedure of melting and solidification.
Abstract: Considering the harm that residual stress causes to the mechanical properties of a weld joint, the evolution mechanisms of transient strain and residual stress distribution are investigated in laser welding of Al 6061, considering that these originate from non-uniform temperature distribution and are intensified further by the unbalanced procedure of melting and solidification. Thermal-elastic-plastic finite element method is developed and analyzed, while the actual weld profile is novel fitted by a B-spline curve. Transient strain is extracted by strain gauges. Longitudinal strain starts from a fluctuating compressive state and progresses to an ultimate residual tension state at the starting and ending welding positions, respectively. The maximum fitting deviation of the weld profile is 0.13 mm. Experimental and simulation results of residual strain are 842.0 μ and 826.8 μ, with a relative error of 1.805% at the starting position and −17.986% at the ending position. Near the weld center, mechanical behavior is complexly influenced by thermal expansion and contraction in the weld zone and the reaction binding force of the solid metal. Within a distance between −10 mm and 10 mm, and longitudinal stress is in a tension state, transverse stress fluctuates with a high gradient (~100 MPa).
3 citations
TL;DR: In this paper , a finite element simulation and theoretical analysis were carried out for the FSW process and finite element model was established by using the SYSWELD software, and the numerical simulation method was used to analyze the temperature field.
2 citations
TL;DR: In this article , an ANSYS finite element model of heavy-duty cutting tools is established based on thermal elastic-plastic theory in order to analyze thermal stress field distribution in welding process, and actual welding residual stress distribution is obtained by the nano indentation experiment, verifying that the model can effectively analyze the stress and strain distribution.
Abstract: Abstract Because of its characteristics of good rigidity and strong ant-vibration, heavy-duty welding turning tools are widely applied in the rough machining of water chamber heads. However, welding residual stress is induced around the welding seam of the tool. During the heavy-duty machining, cracks easily occur due to an influence of impacts, high-temperature and thermal-mechanical loading, which causes tools failure. In this paper, ANSYS finite element model of heavy-duty cutting tools is established based on thermal elastic-plastic theory in order to analyze thermal stress field distribution in welding process. Secondly, actual welding residual stress distribution is obtained by the nano indentation experiment, verifying that the model can effectively analyze the stress and strain distribution. The welding tool failure mechanism is explored further. Finally, vibration aging and ultrasonic impact treatment methods are adopted to reduce welding residual stress of heavy-duty cutting tools. Two methods are compared for the influence of welding residual stress. Through the above research, finite element model can exactly reflect the welding residual stress distribution. The ultrasonic impact treatment is better than vibration aging treatment to reduce the welding residual stress and then extend their service life.
2 citations
TL;DR: In this article , the authors deal with the effect of residual stresses' magnitude and distribution during the formation and the final springback of the seamed pipe end section with and without respect to the influence of the preceding welding.
Abstract: Concerning the increasingly widespread utilization of the finite element method (FEM), the concept of the so-called virtual factory is also gaining ground, and not only in the engineering industry. This approach does not use numerical simulations of individual production technologies separately but treats the entire production process as a chain of interrelated technologies. Thus, the output data from one technology is taken as input data for the following technology. The resulting thermal and mechanical effects are then not only dealt with within one technology but always comprehensively within the production process. In the consideration of the loading and subsequent service lives of manufactured components, values of residual stresses are one of the very important characteristics. For these reasons, this paper deals with the effect of residual stresses’ magnitude and distribution during the formation and the final springback of the seamed pipe end section with and without respect to the influence of the preceding welding. The resulting residual stress values from numerical simulations are subsequently compared with the actual values of residual stresses experimentally measured using X-ray diffraction.
1 citations
References
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16 May 2003
37 citations
TL;DR: In this paper, an analytical model and ABAQUS finite element model are proposed for investigating the three-roll bending forming process, and a reasonably accurate relationship between the downward inner roller displacement and the desired springback radius (unloaded curvature radius) of the bent plate is yielded by both analytical and finite element approaches, which all agree well with experiments.
Abstract: The three-roll bending forming of sheet metal is an important and flexible manufacturing process due to simple configuration. It is suitable for forming large sheet parts with complex, curved faces. Most researches on roll bending forming of large workpiece are mainly based on experiments and explain the process through macroscopic metal deformation. An analytical model and ABAQUS finite element model (FEM) are proposed in this paper for investigating the three-roll bending forming process. A reasonably accurate relationship between the downward inner roller displacement and the desired springback radius (unloaded curvature radius) of the bent plate is yielded by both analytical and finite element approaches, which all agree well with experiments. Then, the three-roll bending forming process of a semi-circle-shaped workpiece with 3,105 mm (length) × 714 mm (width) × 545 mm (height) is simulated with FEM established by the optimum tool and process parameters. Manifested by the experiment for three-roll bending forming of this workpiece, the numerical simulation method proposed yields satisfactory performance in tool and process parameters optimization and workpiece forming. It can be taken as a valuable mathematical tool used for three-roll bending forming of large area sheet metal.
28 citations
"Finite Element Analysis of Residual..." refers methods or result in this paper
...The obtained results were more precise than those in [1, 3]....
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...Under annealing and extrusion conditions, its plasticity is good, while the weld compactness and plasticity can be ensured by using argon arc welding [3, 4], while the strength of the welding joint using gas welding and spot welding is 90–95% of the base metal’s one, and the joint has good cutting performance....
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...Noteworthy is that software design and technological parameters of aluminum alloys welded by the MIG in [1, 3] were different from those used in this work, because the welding quantity of automatic TIG outperforms that of MIG for the same conditions, while MIG is usually used for welding thin plates, i....
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TL;DR: In this paper, the effect of weld characteristics on the forming behaviors of the welded tube was investigated using finite element models which consider the geometric profile and mechanical properties of the welding and heat-affected zones (HAZ).
Abstract: The weld profiles, weld width, weld positions, and mechanical property changes in the weld and heat-affected zones (HAZ) are the most important parameters that influence the potential formability of the welded tube. To investigate the effect of weld characteristics on the forming behaviors of the welded tube, finite element models which consider the geometric profile and mechanical properties of the weld and HAZ are employed. The results show that (1) the mechanical constitutive relation of the weld region determined by the microhardness empirical formula obviously decreases the tangent strain, thickness strain, and cross-sectional deformation ΔD in the weld and HAZ as compared with that determined by the improved rule of mixtures, which is contrary to the hoop strain, and the predicted results determined by the improved rule of mixtures are much closer to the experimental ones; (2) different weld and HAZ widths determined by the microhardness profile and metallographic section have a little effect on the tangent strain, thickness strain, and ΔD distribution; (3) the implementation of weld profile and material properties decreases the wall variation of the weld region as the weld line locates on the outside and inside. On the contrary, both the weld profile and weld material properties increase the maximum ΔD. The sectorial weld profile has a stronger effect on the wall variation and maximum ΔD than the hourglass profile; and (4) the same weld and HAZ volume have a stronger effect on wall thinning and ΔD.
9 citations
Journal Article•
TL;DR: Based on the ANSYS, the calculation flow of residual stress for welding is proposed, which is realized by program using APDL as mentioned in this paper, which has good direction for the optimisation of welding technology.
Abstract: Based on the ANSYS, the calculation flow of residual stress for welding is proposed, which is realized by program using APDL. Using this method, an example to simulate the magnitude and distribution in welding joint is given; the simulation results have good agreement with the experiment results. This method has good direction for the optimisation of welding technology.
7 citations
17 May 2013
TL;DR: In this article, a coupled thermomechanical-metallurgical finite element analysis (FEA) method has been developed to investigate the deformation behavior and to predict the forming capability of 3DQ.
Abstract: The automotive industry has been focusing on developing lighter vehicles to improve fuel economy and crash safety. In order to meet these requirements, Three Dimensional Hot Bending and Direct Quench (3DQ) Technology has been developed, which enables a manufacturer to form hollow tubular automotive parts with a tensile strength of 1,470 MPa or over. 3DQ is a type of consecutive forming that allows bending and quenching at the same time, with a tube feeding device, an induction heater, a cooling device, and a bending device. In this research, a coupled thermomechanical-metallurgical finite element analysis (FEA) method has been developed to investigate the deformation behavior and to predict the forming capability of 3DQ. In the developed FEA procedure, the temperature distribution was calculated with electro magnetic and heat transfer analysis, and the flow stress was defined by transformation models and linear mixture rule. An experimental formula was used to track the ferrite-austenite transformation, and a Koistinen-Marburger relationship was employed to describe austenite-martensite change. The simulated results were compared with the experimental measurements, and the effectiveness of the developed FEA method was confirmed. Furthermore, the deformation characteristics of 3DQ, such as the wrinkling limit and the thickness change, were investigated, and simple equations to describe them were proposed.
5 citations