Abstract

Numerical simulation of welding process in the industrial field requires flexibility, speed, and accuracy at the same time. The use of conventional 3D models in detailed simulations of multi-pass welds is time-consuming, and it often slows down the design phase of large welded structures. Shell elements are usually employed in the finite element (FE) simulation of large structures like vessels and pipes. Nevertheless, employing a simple shell model to simulate multi-pass welds would most likely produce inaccurate outcomes. This article introduces a new equivalent parametric modeling methodology for the simulation of longitudinal multi-pass welds on plane structures, such as plates and rectangular hollow sections. The proposed Weld Equivalent Model (WEM) is made with single and multi-layer shell, link and beam elements. It helps detect residual stress and local distortion that are typical of multi-pass welds. This method employs thermal transient and steady-state structural analyses. The WEM model is generated by an automatic subroutine acting on a pre-existing FE shell model. In addition to this, a case study is reported of multi-pass welding of two plates featuring a V-shaped groove. This innovative weld modeling technique shows remarkable results and helps shorten computational time up to ten times compared to classical 3D numerical models.

摘要

工业领域焊接过程的数值模拟同时需要灵活性、速度和准确性。在多道焊缝的详细模拟中使用传统的 3D 模型非常耗时，而且通常会减慢大型焊接结构的设计阶段。壳单元通常用于容器和管道等大型结构的有限元 (FE) 模拟。然而，使用简单的壳模型来模拟多道焊缝很可能会产生不准确的结果。本文介绍了一种新的等效参数化建模方法，用于模拟平面结构（例如板和矩形空心型材）上的纵向多道焊缝。建议的焊接等效模型 (WEM) 由单层和多层壳、连杆和梁单元构成。它有助于检测多道焊典型的残余应力和局部变形。该方法采用热瞬态和稳态结构分析。WEM 模型由一个自动子程序生成，该子程序作用于预先存在的 FE 壳模型。除此之外，还报告了对具有 V 形坡口的两块板进行多道焊接的案例研究。与经典的 3D 数值模型相比，这种创新的焊接建模技术显示出显着的结果，并有助于将计算时间缩短十倍。一个案例研究报告了两个具有 V 形坡口的板的多道焊接。与经典的 3D 数值模型相比，这种创新的焊接建模技术显示出显着的结果，并有助于将计算时间缩短十倍。一个案例研究报告了两个具有 V 形坡口的板的多道焊接。与经典的 3D 数值模型相比，这种创新的焊接建模技术显示出显着的结果，并有助于将计算时间缩短十倍。