Professional Documents
Culture Documents
Badri Athreya
Caterpillar, Inc.
Peoria, Ill
Related
Distortion Control:
Costs Reduction, Advanced Weld
Fabrication Methods, Fixture Design
Related
Microstructure Control:
Performance, Hardness, MartensiteBanite-Ferrite-Pearlite
F. W. Brust (LEADER)
Z. Cao
(Thermal)
J. Oh (Constitutive Models))
N. Ghadiali (GUI)
T. Forte
J. Hong (General)
F Jakob
(Thermal)
V. Li
(Structural/Materials)
J. Saunders (Thermal)
X. Sun
(Thermal/Mechanical)
Y. Yang
(Experimental/Structural)
J. Zhang (Thermal/Structural)
J. C. Kennedy
Caterpillar
L. Chuzoy
(Consultant)
Y. Dong
(Thermal/Structural)
T. Jutla
(General)
A. Nanjundan
(Thermal/Structural)
C. Sieck
(Consultant)
I. Varol
(Experimental)
D. Blunier
(General)
H. Ludwig
(Experimental/Welding)
P. Crilly
X. L. Chen
Z. Yang
B. Athreya
o
o
o
Weld Info
processor
FEM Mesh
CUBIT
CTSP
DFLUX
GUI
Thermal Model
FZ2
HAZ2
2
1
ABAQUS
BM
HAZ1
Structural Model
Stresses
Distortions
Post processor
Innovative Structural Integrity Solutions
UMAT-WELD
4
3.
4.
5.
6.
Weld Sequencing
Weld Parameter Definition (torch speed,
groove geometry, weld size, heat input, etc.)
Weld Procedure (fusion, electron beam, laser,
friction stir, hybrid laser/MIG, .)
Fixture Design (constraints, tack welds, ..
Pre-camber (elastic)
Peening (LSP, classical, etc.) - local
Ship Hull
Track-Type Tractor
Roller Frame
Articulated Truck
Case & frame
Wheel Loader
Boom
Track-Type Tractor
Case & frame
Barge Loader
Excavator
Moment Arm
Reactor
Frame
Bi-Metallic
Nuclear Pipe
Ferritic
Stainless
Steel
Steel
D
7 pass V-groove
4
3 2
1
2
1
3rdQrtReview.
10/7/20
4
3 2
1
Root pass,1,2,3,4,5,6,7
8 pass V-groove
4
3
2
1
A
D
B
C
3rdQrtReview.
10/7/20
6
4
3
2
1
8 pass V-groove
Number of Nodes: 16257
Number of Elements: 13288
4
2 3
1
3
1 2
Curve T-fillet
(1 pass bevel weld; 3 pass T-fillet)
3rdQrtReview.
10/7/20
10
Distortion Comparison
20
Multi-pass Specimen
Displacement (mm)
15
10
Laser #4
LS4_predicted
D
-5
0
2500
5000
7500
10000
12500
B
C
20
15000
Time (Sec.)
LS4
LS7
Displacement (mm)
15
10
5
Laser #7
LS7_predicted
0
-5
0
2500
5000
7500
10000
12500
15000
Time (Sec.)
Innovative Structural Integrity Solutions
3rdQrtReview.
10/7/20
11
20
4
3
2
1
Laser #3
Laser #4
Laser #7
Laser #8
15
LS4
LS8
LS3
LS7
Original
Design
10
-5
2500
5000
7500
10000
Time (Sec.)
12500
7
5
New
Design
4
3
2
1
Displacement (mm)
15000
3rdQrtReview.
10/7/20
12
13
Pre_cambering
3.0
4.0
4.0
2.0
2.0 2.0
3.0
3.0
Original Geometry
5.9 mm
8.24 mm
Deformed Geometry
Fixture - Version n
and Pre-cambering Scheme
New fixture design
locates drawbar facing up
-1.0
-1.0
2.0
0.0
-1.0
3.0
2.0
-1.0
2.0
4.0
3.0
15
Final Distortion
16
17
Concern:
Sub 1
Sub 2
Simulation:
Sequence
Fixture
Tack weld
Weld size (heat input)
Sub 1
18
19
Transverse Stress
Normal Stress
Prediction
Neutron Diffraction
Measurement
20
Longitudinal Stress
Transverse Stress
Normal Stress
Prediction
Prediction
21
22
TWI and UK MOD: Proceedings of Canada Defense Conference (Halifax, NS, 2007)
Bagshaw and Mawalla (Using VFT)
194 welds
90 Vertical (Tee Fillet)
104 Horizontal (Tee Fillet and Butt)
10 m
Blue (4mm)
Yellow (6 mm)
Green (7 mm)
Red (8mm)
23
23
24
225Degree
Station
Y
X Z
180-Degree Station
25
Innovative Structural Integrity Solutions
Y
Z
90Degree
Repair
135Degree
Station
135-degree
135-degree
Grind/Repair Grind/Repair
End Location Start Location
Summary Bimetallic
Welding
da/dt = C(KI)p
26
Summary
Chen, X. L., Yang, Z, and Brust, F. W., , Modeling Distortion and Residual Stress During
Welding, Chapter 7 in Processes and Mechanisms of Welding Residual Stress and Distortion,
pp. 225 263, Woodhead Publishing, July 2005, ed. Z. Feng.
Brust, F. W., and Kim, D., Mitigating Welding Residual Stress and Distortion, Chapter 8 in
Processes and Mechanisms of Welding Residual Stress and Distortion, pp. 264 294, Woodhead
Publishing, July 2005, Z. Feng, Editor.
27
Machining
Welding
Fixturing
& Tacking
Forming
Cutting
Cleaning
Materials
28
bbrust@emc-sq.com
david.rudland@nrc.gov
29
Back-up
Pre-camber
Amount
-4.7
-4.6
Final Distortion
With
Pre-cambering
-0.136
-0.155
-0.489
Fig.
12 Tee-Fillet
Innovative Structural Integrity
Solutions
31
Bent Plate
3rdQrtReview.
10/7/20
32
TM
Code
ANALYSIS PROCEDURE:
1. ABAQUS Analysis Extract Stress Intensity
Factor (K)
2. Crack Growth for all crack tip points
33