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Part 1: Finite Element Modelling Of A Single Pass Weld

Current commercial nonlinear finite element codes have the capability of modeling the formation of residual stress due to welding. However, considerable care must be taken in defining heat transfer and material properties and in modeling the nonlinearities of the process. The authors describe the development of such a model indicating the necessary modeling features with an example of a bead on plate weld. Experimental confirmation supports the use of the model.

Part 2: Finite Element Analysis of Multi-Pass Welds

An investigation has shown that it is feasible to predict weld residual stress in multipass welds through complete simulation of all passes. However, because of computing costs analyses will be limited to weldments with only two or three passes. For larger weldments it appears that a technique of grouping weld passes in the stress analysis can be used to obtain accurate results without the high cost of a complete simulation.

A method of grouping weld passes in a layer of weld passes into two analyses, one involving all passes in the layer except the last pass and the other involving the last pass only, gave results that are identical to a complete simulation. It is believed that repeating this technique for each layer of a multipass weld will give accurate residual stresses without the high cost of a complete simulation.

Part 3: Thermal and Mechanical Simulations of Resistance Spot Welding

The purpose of this paper is to review analytical studies concerned with simulating the thermal, electrical and mechanical cycles seen in resistance spot welding. Analysis and simulation are valuable tools for gaining a deeper understanding of this type of welding. In particular, nugget formation and the buildup of residual stresses can be simulated, and the influence of process variables can be studied. Furthermore, the similarity of resistance welding simulations to simulations of other manufacturing processes (e.g., grinding) will be discussed along with the prerequisites for performing a realistic simulation.

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Published: 1990 Number of Pages: 47 File Size: 1 file , 5.8 MB