Review on Mitigation of Welding-Induced Distortion Based on FEM Analysis

Wu, Chunbiao; Kim, Jae-Woong

doi:10.5781/jwj.2020.38.1.6

Cited by 14 publications

(8 citation statements)

References 35 publications

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“…Wu suggested that mechanical and thermal balance techniques be developed during the welding process to control welding distortion by reducing welding thermal gradients and producing a tensile stress field near the welded region. A review of these approaches would be beneficial in order to fully understand the main mechanism of mitigating welding-induced distortion and to select the most appropriate method for minimizing deformation based on realistic fabrication demands [ 22 ]. However, welding distortion can be precisely predicted during the manufacturing process while accounting for both local shrinkage and root gap.…”

Section: Introductionmentioning

confidence: 99%

Grey Relational Analysis and Grey Prediction Model (1, 6) Approach for Analyzing the Electrode Distance and Mechanical Properties of Tandem MIG Welding Distortion

et al. 2023

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The tandem metal inert gas (MIG) process uses two wires that are continuously fed through a special welding torch and disbursed to form a single molten pool. Within the contact tip of the modern approach, the wires are electrically insulated from one another. This study identified the effect of welding electrode spacing on the distortion of AA5052 aluminum plates and different mechanical properties including hardness and thermal cycle using grey relational analysis. Plate distortion was subsequently predicted using the grey prediction model GM (1, 6). This research used a pair of 400 mm × 75 mm × 5 mm of AA5052 plates and electrode distances of 18, 27, and 36 mm. The welding current, voltage, welding speed, and argon flow rate were 130 A, 23 V, 7 mm/s, and 17 L/min, respectively. The temperature was measured using a type-K thermocouple at 10, 20, 30, and 40 mm from the center of the weld bead. The smallest distortion at an electrode distance of 27 mm was 1.4 mm. At an electrode distance of 27 mm, the plate may reach a proper peak temperature where the amount of heat input and dissipation rate are similar to those for electrode distances of 18 mm and 36 mm. The highest relative VHN of 57 was found in the BM, while the lowest, 46, was found in the WM, showing good agreement with their respective grain sizes. Six parameters were designed using grey relational analysis (GRA) and subsequently employed in the grey prediction model GM (1, 6). Process evaluation results show that predictions for welding distortions are consistent with actual results, thus, the GM (1, 6) model can be used as a predictive model for welding distortions of 5052 aluminum plates.

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Section: Introductionmentioning

confidence: 99%

Grey Relational Analysis and Grey Prediction Model (1, 6) Approach for Analyzing the Electrode Distance and Mechanical Properties of Tandem MIG Welding Distortion

et al. 2023

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“…Such a model needs less analysis time and is consistent with the experimental results to some extent. Recently, Wu and Kim [22] provided a comprehensive literature review of various techniques to reduce and optimize the deformation induced by welding in the design stage and manufacturing process. Rong et al [23] provided the research status on the welding distortion and residual stress prediction by FE analysis.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Analysis on Welding-Induced Distortion of Automotive Rear Chassis Component

Kim

Bae

Hong

et al. 2022

Metals

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Welding-induced distortion is a major concern for the industrial joining practice. The welding-induced distortion at the weldment between the coupled torsion beam axle (CTBA) of the automotive rear chassis parts and trailing arm connected to the wheel hub axle module seriously affects the tow angle, camber angle, and caster of the wheel axle. In this paper, the welding process between CTBA and trailing arm was numerically analyzed via SYSWELD (i.e., a finite element analysis code), using the material properties predicted via J-MatPro SW, material properties software, considering the thermo-mechanical-metallurgical properties of materials. From the numerical study for the weldment of CTBA and trailing arm, we predicted the welding and thermal distortions, temperature variation, microstructure, and residual stress at the concerned area. As a result, the temperature of the welded area was predicted between 102 °C and 840 °C at the end of weldment and converged to room temperature after 1000 s. The maximum portion of the martensite structure at the welded area was expected to be 55%. The expected distortions of the trailing arm after the weldment were 0.52 mm, −1.47 mm, and 0.44 mm in the x, y, and z-directions, respectively. Finally, the limitations of this research and recommendations are presented.

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“…To minimize trial and error, it is advantageous to verify design feasibility through the finite element method at the design stage, and this is an approach widely used in academia as well as in industry. The finite element method has the advantage of being able to verify design feasibility at a much lower cost compared with experiments or deriving the optimal design through case studies under various conditions [ 7 , 8 ].…”

Section: Introductionmentioning

confidence: 99%

A Study to Derive Equivalent Mechanical Properties of Porous Materials with Orthotropic Elasticity

Pyo

Kim

et al. 2021

Materials

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The need for diverse materials has emerged as industry becomes more developed, and there is a need for materials with pores in various industries, including the energy storage field. However, there is difficulty in product design and development using the finite element method because the mechanical properties of a porous material are different from those of a base material due to the pores. Therefore, in this study, a Python program that can estimate the equivalent property of a material with pores was developed and its matching was verified through comparison with the measurement results. For high-efficiency calculation, the pores were assumed to be circular or elliptical, and they were also assumed to be equally distributed in each direction. The material with pores was assumed to be an orthotropic material, and its equivalent mechanical properties were calculated using the equivalent strain and equivalent stress by using the appropriate material property matrix. The material properties of a specimen with the simulated pores were measured using UTM, and the results were compared with the simulation results to confirm that the degree of matching achieved 6.4%. It is expected that this study will contribute to the design and development of a product in the industrial field.

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Review on Mitigation of Welding-Induced Distortion Based on FEM Analysis

Cited by 14 publications

References 35 publications

Grey Relational Analysis and Grey Prediction Model (1, 6) Approach for Analyzing the Electrode Distance and Mechanical Properties of Tandem MIG Welding Distortion

Grey Relational Analysis and Grey Prediction Model (1, 6) Approach for Analyzing the Electrode Distance and Mechanical Properties of Tandem MIG Welding Distortion

Finite Element Analysis on Welding-Induced Distortion of Automotive Rear Chassis Component

A Study to Derive Equivalent Mechanical Properties of Porous Materials with Orthotropic Elasticity

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