Novel welding distortion analysis method for large welded structures using orthotropic thermal expansion coefficients

Seo, Hyunduk; Lee, Jaemin

doi:10.1093/jcde/qwab035

Cited by 3 publications

(1 citation statement)

References 18 publications

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“…Granell et al [7] used the thermal-mechanical coupling model based on the birth and death element to accurately predict the welding deformation process. Seo et al [8] used scalar input variables to modify the traditional inherent strain theory to accurately predict transverse shrinkage and angular deformation and eliminate unnecessary longitudinal forces. Yuan et al [9] adopted the finite element method based on thermal-structural coupling calculation to study the welding deformation of copper alloy sheets.…”

Section: Introductionmentioning

confidence: 99%

Deformation Evolution Law of Surfacing Welding on Thin Bending Plates Based on the Three-Dimensional Thermal Digital Image Correlation Method

Guo

Yang

et al. 2022

Coatings

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Surfacing on the surface of thin metal bending plates will cause significant deformation, and current numerical simulation and experimental methods cannot fully and truly reflect the deformation state of the bending plate. In this paper, a non-contact detection method based on the three-dimensional (3D) thermal digital image correlation (DIC) method is proposed. The proposed method can be used for the 3D full-field dynamic measurement of metal thin bending plate surfaces. In addition, the evolution law of in-plane and out-of-plane deformation of thin bending plates during surfacing welding and cooling was studied. Moreover, the influence of curvature on the shrinkage deformation of thin bending plate weld was explored, and the correlation between the curvature of thin bending plates and the weld shrinkage was established. Results show that the proposed detection method based on the 3D thermal DIC method can rapidly and accurately detect bending deformation online. The out-of-plane deformation of the surfacing welding of the thin bending plate transits from the disk to the saddle. Furthermore, the curvature of the thin bending plate is inversely proportional to the transverse shrinkage of the weld bead. After the curvature reaches a certain value, it has little effect on the longitudinal shrinkage of the weld bead. This detection method solves the problem of welding deformation simulation verification, truly clarifies the law of welding dynamic deformation, and provides a theoretical basis for welding lightweight manufacturing.

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Section: Introductionmentioning

confidence: 99%

Deformation Evolution Law of Surfacing Welding on Thin Bending Plates Based on the Three-Dimensional Thermal Digital Image Correlation Method

Guo

Yang

et al. 2022

Coatings

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Computational analysis of metal transfer mode, dynamics, and heat transfer under different pulsating frequencies in pulsed wire-arc additive manufacturing

Ikram

Chung

2022

Journal of Computational Design and Engineering

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A numerical model of the metal transfer process was developed using the thermomagnetohydrodynamic equations and the phase-field method to investigate the influence of pulse frequency on the metal transfer mode, dynamics, and thermal behavior in the pulsed wire-arc additive manufacturing (WAAM) process. The control of droplet transfer mode, dynamics, and thermal behavior is essential in WAAM; otherwise, several potential defects such as high residual stresses and distortion, poor dimensional accuracy, and surface quality may occur due to uneven heat input condition and process instability. Therefore, in this study, eight sets of pulse frequencies ranging from 50 to 225 Hz, in steps of 25 Hz, using identical power source parameters, such as pulse duty cycle and average current of 25.4% and 152 A, respectively, were considered and compared for a nearly square current waveform. The results reveal that only the current pulses with a medium frequency regime (100–175 Hz) achieve the one-droplet-per-pulse mode of metal transfer. Moreover, an increase in pulse frequency leads to a shorter necking length of the pendent droplet and a significantly lower average speed and temperature of the detached droplet. The results for the heat flux analysis indicate that Joule heating and arc heating decrease due to the increase in pulse frequency, whereas the sheath heating remains almost constant using different pulse frequencies. The proposed numerical scheme provides a detailed understanding of controlling and tailoring the different metal transfer modes and their metal transfer stability during WAAM, which benefits further process optimization and control.

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Welding simulation using a reduced order model for efficient residual stress evaluation

Shin

Boo

2022

Journal of Computational Design and Engineering

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In this paper, to evaluate the residual stress of welded structures efficiently, we propose a welding simulation method utilizing a reduced order model. To construct the reduced order model, a finite element model is divided into a target part and an omitted part. For the heat transfer analysis, a thermal boundary condition is newly defined and applied to the target part, to compensate for the heat loss induced by neglecting the omitted part. For the thermal elastic plastic analysis, a reduced model for the target part is constructed using the automated static condensation method. The performance of the proposed welding simulation method adopting the reduced order model is verified by solving several welding problems, and it effectively reduces computational costs while predicting the residual stress with little loss of accuracy.

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Novel welding distortion analysis method for large welded structures using orthotropic thermal expansion coefficients

Cited by 3 publications

References 18 publications

Deformation Evolution Law of Surfacing Welding on Thin Bending Plates Based on the Three-Dimensional Thermal Digital Image Correlation Method

Deformation Evolution Law of Surfacing Welding on Thin Bending Plates Based on the Three-Dimensional Thermal Digital Image Correlation Method

Computational analysis of metal transfer mode, dynamics, and heat transfer under different pulsating frequencies in pulsed wire-arc additive manufacturing

Welding simulation using a reduced order model for efficient residual stress evaluation

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