Research Papers

A Plane Stress Model to Predict Angular Distortion in Single Pass Butt Welded Plates With Weld Reinforcement

[+] Author and Article Information
Junqiang Wang

School of Mechanical,
Electronic and Control Engineering,
Beijing Jiaotong University,
Beijing 100044, China;
Aluminum Corporation of China,
Beijing 102209, 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

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

Zhiqiang Li, Yingxin Zhao, Luyi Sun

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

1Corresponding author.

Manuscript received July 23, 2016; final manuscript received November 30, 2016; published online January 30, 2017. Assoc. Editor: Wayne Cai.

J. Manuf. Sci. Eng 139(5), 051012 (Jan 30, 2017) (10 pages) Paper No: MANU-16-1404; doi: 10.1115/1.4035469 History: Received July 23, 2016; Revised November 30, 2016

While coupled three-dimensional (3D) nonisothermal finite-element (FE) models can be used to predict distortion in weldments, computational costs remain high, and the development of alternate FE-based engineering approaches remains an important topic. In the present study, a plane stress model is proposed for analyzing angular distortion in butt-welded plates having appreciable levels of weld reinforcement. The approach is based on an analysis of contractile shrinkage forces and only requires knowledge of the plastic zone geometry to develop the input data needed for an isothermal linear elastic FE model. Results show that the proposed method significantly reduces the computational time and provides acceptable accuracy when plane stress conditions are satisfied. The effect of weld reinforcement was also analyzed using the method. The results indicate that the contraction force from the bead is dominant, and that the primary effect of the crown is to increase eccentricity of the in-plane contraction force. A steel liner from a nuclear plant cooling tower was also analyzed to demonstrate the method. The results showed that the model was able to predict the distortion pattern and demonstrated fair accuracy.

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Fig. 1

Schematic representation of a full penetration butt weld depicting the transverse shrinkage volume geometry and nomenclature used

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Fig. 2

Representation of (a) equivalent body force and (b) resolved components acting on a point p in a weld

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Fig. 3

Schematic depiction of the transverse shrinkage force and rectangular elements used to represent the plastic strain regions in the bead and crown

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Fig. 4

Representation of (a) equivalent body force and (b) resolved components acting on a point p′ in an equivalent plane stress weld representation

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Fig. 5

Schematic of plane stress model showing: (a) the midplane and (b) eccentricity e′ from the midplane

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Fig. 6

Three-dimensional finite-element representation of the experimental GMA weldments with dimensions noted

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Fig. 7

Mechanical and thermophysical parameters of ASTM A572-50 steel shown as a function of temperature after [13,14]

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Fig. 8

Plane stress finite-element representation of the experimental GMA weldments with equivalent weld width indicated

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Fig. 9

Comparison of CPU times obtained from the 3D coupled and 3D plane stress models where the range of simulation times for each method is indicated by parallel dashed lines

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Fig. 10

Finite-element representation of the (a) steel liner that was analyzed and (b) close-up of angle steel reinforcements

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Fig. 11

Plate and weld arrangement used to fabricate the steel liner

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Fig. 12

Simulated radial deformation in the welded steel liner obtained from the plane stress model

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Fig. 13

Comparison of predicted and actual radial deflection at selected points on the upper periphery of the welded steel liner




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