Welding distortion prediction with elastic FE analysis and mitigation practice in fabrication of cantilever beam component of jack-up drilling rig

Wang, Jiangchao; Zhao, Hu; Zou, Jiasheng; Zhou, Hong; Wu, Zhengfeng; Du, Shizhong

doi:10.1016/j.oceaneng.2016.11.059

Cited by 48 publications

(10 citation statements)

References 15 publications

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“…Wang et al 12) reported that an elastic FEM analysis based on inherent deformation theory and interface element is an effective and practical computational approach for welding distortion prediction in the fabrication of large-scale welded offshore structures. Moreover, Wang et al 13) employed an inherent deformation method to evaluate welding distortion of the spherical welded structure produced by multi welding lines within a very short computing time. On the other hand, the problem-solving idea of the equivalent thermal strain method is that the inherent strain is directly entered as the equivalent thermal strain to the FEM model.…”

Section: Introductionmentioning

confidence: 99%

Welding Distortion Prediction for Multi-Seam Welded Pipe Structures using Equivalent Thermal Strain Method

Wang

Kim

2021

Journal of Welding and Joining

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Distortion prediction of a welded structure is an important way to improve work efficiency and ensure product quality during the fabrication process. Recently, the widely used approaches for evaluating residual deformation include the thermo-elastic-plastic finite element method (TEP-FEM) and the inherent strain method (ISM). The former can accurately simulate the entire welding process with excessive computational time, whereas the latter has great potential in the fast prediction of residual distortion in complex welded components. In this study, an equivalent thermal strain method based on inherent strain theory was proposed to predict residual deformation of the multi-seam welded pipe structures. Moreover, a full 3D TEP-FEM model was also developed to estimate the distributions of inherent strain in longitudinal (L-seam) and circumferential (C-seam) welds. To validate the accuracy of the proposed ISM, the welding distortion predicted by the proposed ISM is compared with the experimental data and TEP-FEM simulation results. It is discovered that the proposed ISM can be used to accurately predict welding-induced deformation in multi-seam welded pipe structures. Furthermore, compared with TEP-FEM simulation, the significant advantage of this approach is that the computing efficiency can be increased by about 50 times.

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Section: Introductionmentioning

confidence: 99%

Welding Distortion Prediction for Multi-Seam Welded Pipe Structures using Equivalent Thermal Strain Method

Wang

Kim

2021

Journal of Welding and Joining

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“…With the rapid development of lightweight fabrication in ship industry, thick plate with high tensile strength steel was increasingly employed for marine and offshore structure fabrication [1]. Welding technology with high efficiency is an indispensable process used for ship and offshore fabrication.…”

Section: Introductionmentioning

confidence: 99%

Residual Stress Evaluation with Contour Method for Thick Butt Welded Joint

Zhang¹,

Zhou²,

Wang³

2020

New Challenges in Residual Stress Measurements and Evaluation

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Thick plate with high tensile strength steel is increasingly employed for offshore structure fabrication, and welding residual stress is essential for assessment of mechanical performance and fatigue toughness. Therefore, it has been becoming the research issue to evaluate the distribution and magnitude of welding residual stress during butt welding of thick plate. With its advantages, contour method (CM) can be used for longitudinal residual stress evaluation by means of measuring sectional shrinkage after cutting the butt welded joint perpendicular to the welding line. Meanwhile, inverse finite element method (IFEM) code is programmed with C++ language to analyze the measured data to reestablish the welding residual stress. And based on the parallel computation of high-performance server, considering the effect of weld remelting and back-gouging during multi-pass welding process, the welding residual stress is predicted by using efficient thermal elastic plastic finite element method (TEP FEM). Results show that longitudinal residual stress turned from tensile stress in welded vicinity into compressive stress in base metal and the maximum tensile stress is 269 MPa. The computed longitudinal residual stress and welding displacement through TEP FEM are identified with the experimental results. In addition, the back-gouging has an insignificant effect on the residual stress but increases the welding displacement of butt welded joint. The proposed TEP FEM can accurately predict the welding residual stress in welded joint and is also an effective method to control welding displacement.

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“…In the fabrication of complex welded structure with multi-pass welding, welding induced distortion will strongly influence the dimensional accuracy and external appearance, as well as increase fabrication cost when straightening procedure is required and even change fabrication schedule and integral quality. 1–3 For advanced precision fabrication, it is necessary to predict the possible welding distortion in advance before the actual fabrication, clarify the generation mechanism of different welding distortion and then validate the mitigation effect of proposed techniques.…”

Section: Introductionmentioning

confidence: 99%

Effective thermal elastic plastic finite element computation for welding distortion investigation of pozidriv-type welded structure with rectangular pipes and its mitigation

Wang

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Welding distortion of pozidriv-type welded structure with rectangular pipes by 20 welding passes was examined with experimental and computational approaches, and mitigation techniques were also investigated for precision fabrication. Welding experiment to fabricate pozidriv type welded structure was conducted beforehand, and out-of-plane welding distortion was measured with contact type displacement sensor. Effective thermal elastic plastic finite element computation with iterative substructure method and parallel computation was developed, and then employed to examine the thermal-mechanical response during the entire welding process and predict the residual out-of-plane welding distortion. Good agreement between computed results and measurement data was observed with comparison. The influences of welding sequence and clamping constraint with tack welding on welding distortion were considered, which were also practiced for out-of-plane welding distortion mitigation. Both experiment and finite element computation show that out-of-plane welding distortion with welding sequence optimization and clamping constraint can be significantly reduced with about 38% and 56% magnitude of original welding distortion, respectively, while their mechanisms were also clarified by means of stiffness variation of solving welded structure.

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Welding distortion prediction with elastic FE analysis and mitigation practice in fabrication of cantilever beam component of jack-up drilling rig

Cited by 48 publications

References 15 publications

Welding Distortion Prediction for Multi-Seam Welded Pipe Structures using Equivalent Thermal Strain Method

Welding Distortion Prediction for Multi-Seam Welded Pipe Structures using Equivalent Thermal Strain Method

Residual Stress Evaluation with Contour Method for Thick Butt Welded Joint

Effective thermal elastic plastic finite element computation for welding distortion investigation of pozidriv-type welded structure with rectangular pipes and its mitigation

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