Research Papers

Tolerance Analysis Considering Weld Distortion by Use of Pregenerated Database

[+] Author and Article Information
Dongyul Lee

 Ssangyong Motors Company, Pyongtaek, Kyunggi, 459–711, Korea

Ki Eak Kwon

 B2GEN Inc., Seoul, 153-803, Korea

Jaeyeol Lee

 Xinnos Inc., Seoul, 137–839, Korea

Haeseong Jee

 Hongik University, Seoul, 121–791, Korea

Hyunjune Yim1

 Hongik University, Seoul, 121–791, Koreahjyim@hongik.ac.kr

Seong Wook Cho

 Chung Ang University, Seoul, 156–756, Korea

Jong-Gye Shin

 Seoul National University, Seoul, 151–744, Korea

Gyubong Lee

 KITECH, Cheonan, Kyunggi, 331–825, Korea


Corresponding author.

J. Manuf. Sci. Eng 131(4), 041012 (Jul 14, 2009) (8 pages) doi:10.1115/1.3160319 History: Received March 08, 2006; Revised December 03, 2007; Published July 14, 2009

A general and efficient methodology has been developed to analyze dimensional variations of a welded assembly, taking into account of weld distortion. Weld distortion is generally probabilistic because of the random nature of welding parameters such as the welding speed, maximum welding temperature, ambient temperature, etc. The methodology is illustrated by a very simple example of two perpendicular plates fillet-welded to each other. Two steps comprise the methodology: establishment of a weld distortion database and tolerance analysis using the database. To establish the database, thermo-elastoplastic finite element analyses are conducted to compute the weld distortion for all combinations of discrete values of major welding parameters. In the second step of tolerance analysis, the weld distortion retrieved from the database is taken into account in addition to the dimensional tolerances of the parts. As a result of such an analysis, sensitivities of the assembly’s dimensional variations to the part tolerances and weld distortion are obtained, which could provide a guideline for improving dimensional quality of the assembly.

Copyright © 2009 by American Society of Mechanical Engineers
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Figure 1

Schematic diagram of proposed method

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Figure 2

Illustrative example problem of fillet welding of two plates

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Figure 3

Model and boundary conditions for finite element analyses

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Figure 4

An example temperature distribution obtained from finite element heat transfer analysis

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Figure 5

An example of displacement field and deformed shape obtained from FEA

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Figure 6

Vertical displacements at weld starting point A

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Figure 7

Vertical displacements at weld ending point B

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Figure 8

Procedure to retrieve weld distortions from database

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Figure 9

Graphic user interface to define user tolerances of weld distortions

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Figure 10

Dimensional tolerances and measurement points

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Figure 11

Sensitivities of y-variation at point C to tolerances

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Figure 12

Sensitivities of z-variation at point C to tolerances




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