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Acta Metall Sin  2010, Vol. 46 Issue (2): 189-194    DOI: 10.3724/SP.J.1037.2009.00198
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ESTABLISHMENT AND APPLICATION OF FIXTURE CONSTRAINT MODELS IN FINITE ELEMENT ANALYSIS OF WELDING PROCESS
ZHANG Zenglei1; SHI Qingyu1; YAN Dongyang1; CAI Zhipeng1;LI Decheng2
1.Department of Mechanical Engineering; Tsinghua University; Beijing 100084
2.China Academy of Launch Vehicle Technology; Capital Aerospace Machinery Corporation; Beijing 100076
Cite this article: 

ZHANG Zenglei SHI Qingyu YAN Dongyang CAI Zhipeng LI Decheng. ESTABLISHMENT AND APPLICATION OF FIXTURE CONSTRAINT MODELS IN FINITE ELEMENT ANALYSIS OF WELDING PROCESS. Acta Metall Sin, 2010, 46(2): 189-194.

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Abstract  

The mechanical interaction between welded panel and fixture has a remarkable influence on the distribution of weld–induced residual stress and distortion. Unfortunately, the influence of fixture is not generally included in conventional numerical simulations of welding process. In the present study, it is proposed that the numerical models in which the mechanical interaction between welded panel and fixture is considered as contact pair in the finite element analysis (FEA) of welding process. This could make the FEA of welding process more scientific and accurate. The fixture constraint plays an important role in accurate modeling of welding process. In the simulations, various mechanical constraint boundary conditions in welding process were thought about to establish the relationships of the normal and tangential mechanical interactions between welded panel and fixture. In Free model, the fixture restraint was not considered. In Mech model, the displacements of nodes where welded panel contacted with fixture were restricted in x, y, z directions. Hard model and Tabular model were contact models which included the fixture. In the normal direction, once welded panel and fixture were in contact, the transmitted contact pressure could be infinite in Hard model. While data pairs of contact pressure vs over–closure or clearance were specified to define a piecewise–linear relationship in the normal direction in Tabular model. A penalty friction coefficient of 0.3 was applied in tangential direction in both Hard and Tabular models. Fixture and welded panel were separated and the contact relationships were removed after the welding process in both Hard and Tabular models. The simulation results of contact models including fixture were more accurate, compared to models containing only welded panel with rigid retrictions. The distortiomode of welded panels under different fixture constrait conditions corresponded well with xperimental results. The differences between the distributions of transverse sresses on top and bottom surfaces f welded panel at the beginning of welding process had a crucial influence on the distortion mode f welded panel.

Key words:  welding      numerical simulation      fixture constraint      contact algorithm      transverse stress     
Received:  30 March 2009     
Fund: 

Supported by National High Technology Research and Development Program of China (No.2006AA04Z139)

URL: 

https://www.ams.org.cn/EN/10.3724/SP.J.1037.2009.00198     OR     https://www.ams.org.cn/EN/Y2010/V46/I2/189

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