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Possibilities and limitations of geometric simplifications for calculations of residual stresses and distortions

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Abstract

The prediction and minimization of welding distortions and the evaluation of the residual stress state after welding using numerical methods are increasingly gaining importance. These numerical models are used to optimize welding processes with respect to distortion. However, the computational time required for a transient 3-D calculation, particularly for large components, often hinders commercial usage of these approaches. Therefore, simulations have to simplify individual aspects. Due to the fact that model verification often failed according to abundant experimental research efforts, it cannot be proven whether the deformations and residual stresses calculated by those simplified models are trustworthy. With the help of the validated simulations of the IIW round robin tests and of variational calculus, this work shows the influences of sheet geometry and model simplifications, e.g. 2-D modelling, on the calculation of distortions and residual stresses. The round robin tests were performed using steel sheets made of an austenitic steel (316 LNSPH) which was bead-on-plate welded by TIG welding. The calculations for a varied sheet geometry show for the investigated process and for large components that a reduction to minimal sheet geometry is necessary and sufficient to determine the longitudinal stresses and the distortions. The transversal stresses are in general extremely sensitive to the sheet geometry.

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Abbreviations

HAZ:

Heat-affected zone

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Acknowledgments

The authors like to express their gratitude to the Government of the City of Bremen for financial support of the reported work.

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Authors and Affiliations

  1. BIAS Bremer Institut für angewandte Strahltechnik, Klagenfurter Strasse 2, 28359, Bremen, Germany

    Jens Sakkiettibutra & Frank Vollertsen

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  1. Jens Sakkiettibutra
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  2. Frank Vollertsen
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Correspondence to Jens Sakkiettibutra.

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Sakkiettibutra, J., Vollertsen, F. Possibilities and limitations of geometric simplifications for calculations of residual stresses and distortions. Prod. Eng. Res. Devel. 5, 485–495 (2011). https://doi.org/10.1007/s11740-011-0309-y

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  • DOI: https://doi.org/10.1007/s11740-011-0309-y

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