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and
]
are the heat flux distribution factors in the front and rear portion of the arc.
Q = VI
+
]
=2
= efficiency of arc (0.85 is taken for this analysis)
Q = Heat Input (Watts)
V = Voltage (Volts)
I = Current (Ampere)
Fig. 4: The Heat Source Model Used in the Present Study
The heat source parameters used to model the heat source in the present study is given in the table2.
Table 2: Heat Source Parameters Used for Welding
Parameter a
f
a
r
b c f
f
f
r
Size
4
mm
12
mm
8
mm
3.5
mm
0.45 1.55
The Effect of Heat Input & Travel Speed on the Welding Residual Stress by Finite Element Method 47
The temperature history is stored for every time step to be used later for the structural analysis. In the structural
analysis the element type is changed to solid185 using element change command. The boundary constraints are applied and
a transient structural solution is obtained using a separate macro written using APDL. The structural analysis uses the same
time steps and loop used for the thermal analysis.
RESULTS AND DISCUSSIONS
The percentage of ferrite and martensite in the different samples of dual phase steel are measured using point
counting method as per ASTM E562 standard. The percentage of martensite in the dual phase steel is influenced by the
intercritical annealing temperature. The residual stresses in the samples of different martensite content are measured in the
welded region, heat affected zone and base metal by X-ray diffraction test. No significant change in the residual stress
pattern is observed with changes in martensite content. A sequentially coupled thermo mechanical analysis using ANSYS
is carried out to verify the result obtained. The predicted result using ANSYS analysis shows a deviation up to 18%.
The model is further used to study the effect of heat input and travel speed on the residual stresses. The heat input
is varied from 2000W to 3000W and the travel speed from 1mm/sec to 4mm/sec. The residual stresses are found to vary
significantly with the heat input and travel speed. The temperature contour plot at the end of 10 seconds from the start of
the welding is shown in fig.5.
Fig. 5: The Temperature in Kelvin at the End of 10sec from the Start of the Welding for a Heat Input of 2000w and
Travel Speed 4mm/Sec
Fig. 6: Variation of Maximum Longitudinal Residual Stress with Travel Speed
0
100
200
300
400
500
0.5 1.5 2.5 3.5 4.5
L
o
n
g
i
t
u
d
i
n
a
l
R
e
s
i
d
u
a
l
S
t
r
e
s
s
-
M
P
a
Travel Speed - mm/sec
2000W
2500W
3000W
48 P.D.Sudersanan & U.N.Kempaiah
The variation of longitudinal residual stress with travel speeds for different heat input is shown in fig6.The
longitudinal residual stress has decreased considerably with arc travel speed for all heat input values analysed. The same is
found to increase with the heat input for every input of travel speed.
Fig. 7: Comparison of Experimental Longitudinal Residual Stress with FEM for a Heat Input of 2000W and Travel
Speed 4mm/Sec
The longitudinal residual stress obtained from 3D FEM analysis and the experimental result for a heat input of
2000W and travel speed of 4mm/sec is plotted in fig 7. Figures 8-10 shows the ANSYS path plots for Longitudinal and
transverse stress variation across and along the weld line. The contour plot for longitudinal residual stress at the end of
welding is shown in fig.11.
Fig. 8: Longitudinal Residual Stress Distribution in the Transverse Direction at the Centre of the Plate for a Heat
Input of 2000w and Travel Speed 4mm/Sec.
Fig. 9: Longitudinal Residual Stress Distribution Along the weld Bead for a Heat Input of 2000w and Travel Speed
4mm/Sec.
-60
-40
-20
0
20
40
60
80
100
120
140
0 10 20 30 40 50
R
e
s
i
d
u
a
l
s
t
r
e
s
s
i
n
M
P
a
Distance in mm
FEM
EXP
The Effect of Heat Input & Travel Speed on the Welding Residual Stress by Finite Element Method 49
.
Fig. 10: Transverse Residual Stress Distribution Along the Weld Bead for a Heat Input of 2000w Speed and Travel
4mm/Sec.
Fig. 11: Contour Plot of Longitudinal Residual Stress Distribution at the End of Welding for a Heat Input of 2000w
and Travel Speed 4mm/Sec
CONCLUSIONS
The Intercritical temperature has shown a considerable influence on the volume fraction of the dual phase steel
and increased nonlinearly with it. X-ray diffraction tests were carried out on various samples to study the effect of
percentage of martensite in the dual phase steel on the residual stress introduced after welding. The results show no
significant influence of percentage of martensite on the residual stress. The FEM simulation and consequent thermo
mechanical analysis carried out has shown the residual stress increases with heat input. It is also observed that the residual
stress considerably decreases with travel speed. The transverse residual stress induced in the welding is negligible except at
the starting and ending of the weld.
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