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Research Papers

Predicting Distortion in Butt Welded Plates Using an Equivalent Plane Stress Representation Based on Inherent Shrinkage Volume

[+] Author and Article Information
Junqiang Wang, Weijing Li, Zhiyong Yang, Yingxin Zhao

School of Mechanical,
Electronic and Control Engineering,
Beijing Jiaotong University,
Beijing 100044, China

Jianmin Han

School of Mechanical,
Electronic and Control Engineering,
Beijing Jiaotong University,
Beijing 100044, China
e-mail: jmhan@bjtu.edu.cn

Joseph P. Domblesky

Department of Mechanical Engineering
Marquette University,
1515 West Wisconsin Avenue,
Milwaukee, WI 53201-1881

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received October 20, 2014; final manuscript received April 19, 2015; published online September 9, 2015. Assoc. Editor: Wayne Cai.

J. Manuf. Sci. Eng 138(1), 011012 (Sep 09, 2015) (11 pages) Paper No: MANU-14-1552; doi: 10.1115/1.4030460 History: Received October 20, 2014

Due to the adverse effect that distortion has on assembly fit-up and fabrication costs in welded structures, the ability to predict dimensional changes represents an important engineering concern. While distortion can be analyzed using a full three-dimensional (3D) finite element (FE) model, this often proves to be computationally expensive for medium and large structures. In comparison, a two-dimensional (2D) FE model can significantly reduce the time and effort needed to analyze distortion though such analyses often have reduced accuracy. To address these issues, a 3D plane stress model using shell meshes based on the shrinkage volume approach is proposed. By inversing the plastic shrinkage zone geometry, an eccentric loading condition and equivalent plane stress representation can be developed and used to predict distortion in butt welded plates using an isothermal model. The model was validated using deflection data from welded plates and found to provide good accuracy over the range of thicknesses considered. Results obtained from welding of a large containment tank are also presented and further confirm the utility of the method.

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Figures

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Fig. 1

Photograph showing: (a) joint geometry used in the investigation and angular distortion before welded and after welded and (b) experimental setup (shown prior to welding, note tack weld restraints on left plate)

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Fig. 2

Representation of: (a) depiction of the weldment and co-ordinate system used in the analysis and (b) representation of the butt weld depicting the transverse weld zone geometry and forces resulting from thermal contraction

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Fig. 3

Representation of: (a) equivalent thermal body force and (b) resolved components acting on a point p in the weld cross section

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Fig. 4

Representation of: (a) schematic representation of the equivalent plane stress weldment and co-ordinate system used in the analysis and (b) the section of equivalent 2D butt welding model considered the equivalent eccentricity e' in order to produce bending moment m'x

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Fig. 5

Representation of: (a) equivalent thermal body force and (b) resolved components acting on a point p' in the equivalent 2D weld cross section

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Fig. 6

Representation of: (a) 3D FE representation of the ASTM A572-50 weldment showing mesh and nodal constraints and (b) 2D FE representation of the plane stress shell element model

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Fig. 7

Mechanical and thermophysical parameters of ASTM A572-50 steel shown as a function of temperature

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Fig. 8

Comparison of average edge displacement (perpendicular to the plate thickness direction) obtained at different plate thicknesses using the 3D plane stress model and 3D coupled models and experimental butt weld

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Fig. 9

Comparison of simulated distribution from the 3D plane stress models and 3D coupled models: (a) 4 mm thickness, (b) 6 mm thickness, (c) 8 mm thickness, and (d) 10 mm thickness

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Fig. 10

Distribution of predicted vertical displacements obtained from the 3D plane stress models and 3D coupled models

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Fig. 11

Representation of: (a) solid model depicting the inside cover of the municipal treatment tank analyzed using the plane stress model and (b) iso-contour plot of deflection obtained for the municipal tank cover using the plane stress model

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Fig. 12

Comparison of actual and predicted vertical displacements for the welded municipal cover

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