Research Papers

Variation Simulation of Welded Assemblies Using a Thermo-Elastic Finite Element Model

[+] Author and Article Information
Samuel Lorin

Department of Product
and Production Development,
Chalmers University of Technology,
Gothenburg SE-412 96, Sweden
e-mail: samuel.lorin@chalmers.se

Christoffer Cromvik, Fredrik Edelvik

Fraunhofer-Chalmers Centre
for Industrial Mathematics,
Chalmers University of Technology,
Chalmers Science Park,
Gothenburg SE-412 88, Sweden

Lars Lindkvist, Rikard Söderberg

Department of Product
and Production Development,
Chalmers University of Technology,
Gothenburg SE-412 96, Sweden

1Corresponding author.

Contributed by the Design Engineering Division of ASME for publication in the JOURNAL OF COMPUTING AND INFORMATION SCIENCE IN ENGINEERING. Manuscript received December 9, 2013; final manuscript received March 21, 2014; published online April 28, 2014. Editor: Bahram Ravani.

J. Comput. Inf. Sci. Eng 14(3), 031003 (Apr 28, 2014) (6 pages) Paper No: JCISE-13-1275; doi: 10.1115/1.4027346 History: Received December 09, 2013; Revised March 21, 2014

Every series of manufactured products has geometric variation. Variation can lead to products that are difficult to assemble or products not fulfilling functional or aesthetic requirements. In this paper, we will consider the effects of welding in variation simulation. Earlier work that has been combining variation simulation with welding simulation has either applied distortion based on nominal welding conditions onto the variation simulation result, hence loosing combination effects, or has used transient thermo-elasto-plastic simulation, which can be very time consuming since the number of runs required for statistical accuracy can be high. Here, we will present a new method to include the effects of welding in variation simulation. It is based on a technique that uses a thermo-elastic model, which previously has been shown to give distortion prediction within reasonable accuracy. This technique is suited for variation simulations due to the relative short computation times compared to conventional transient thermo-elasto-plastic simulations of welding phenomena. In a case study, it is shown that the presented method is able to give good predictions of both welding distortion and variation of welding distortions compared to transient thermo-elasto-plastic simulations.

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Fig. 1

Contributors of geometric variation

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Fig. 2

A 3-2-1 positioning system often used for rigid bodies

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Fig. 3

Double ellipsoid heat flux [7]

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Fig. 4

The three major steps in the SCV-method: steady-state thermal analysis, computation of two-dimensional melting region, and applying thermal load to the three-dimensional model

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Fig. 5

Temperature distribution and isosurfaces for melting temperature (1300 °C) obtained from a steady-state heat analysis in moving frame

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Fig. 6

The T-joint used in the case study together with the boundary condition of the tack welded structure

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Fig. 7

The three–point locating scheme that positions the web and flange prior to tack welding. Observe that the parts have been separated for visualization only.

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Fig. 8

The mesh used for all welding simulations

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Fig. 9

Magnitude of weld-induced distortion using a transient thermomechanical model

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Fig. 10

Longitudinal stress from transient thermomechanical model compared to experimental measurement [15]

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Fig. 11

Magnitude of distortion predicted by the SCV-method

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Fig. 12

Color-coding showing predicted 6σ of weld-induced distortion



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