WO2001030532A1 - Method and apparatus for providing a simulation of a welding process using integrated models - Google Patents

Method and apparatus for providing a simulation of a welding process using integrated models Download PDF

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Publication number
WO2001030532A1
WO2001030532A1 PCT/US2000/025958 US0025958W WO0130532A1 WO 2001030532 A1 WO2001030532 A1 WO 2001030532A1 US 0025958 W US0025958 W US 0025958W WO 0130532 A1 WO0130532 A1 WO 0130532A1
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WO
WIPO (PCT)
Prior art keywords
welding process
model
analysis
thermal
finite element
Prior art date
Application number
PCT/US2000/025958
Other languages
French (fr)
Inventor
Yi Dong
Ashok Nanjundan
Xiao Chen
Original Assignee
Caterpillar Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Caterpillar Inc. filed Critical Caterpillar Inc.
Priority to CA002384010A priority Critical patent/CA2384010A1/en
Priority to EP00963707A priority patent/EP1242211A1/en
Priority to JP2001532927A priority patent/JP2003512180A/en
Publication of WO2001030532A1 publication Critical patent/WO2001030532A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/095—Monitoring or automatic control of welding parameters
    • B23K9/0953—Monitoring or automatic control of welding parameters using computing means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials

Definitions

  • This invention relates generally to a method and apparatus for modeling a welding process and, more particularly, to a method and apparatus for integrating models for a welding process to perform a thermal and structural analysis of the process.
  • the process of welding materials has some amount of detrimental effect on the materials being welded.
  • materials being welded are subjected to residual stresses and distortions due to the extreme heat caused by the weld process .
  • FEM finite element method
  • Another method used to determine the effects of heat on materials from the welding process incorporates an analytical solution to determine the thermal history of the welding process.
  • analytical solutions have been developed which use the superposition of point heat source solutions. These methods generally do not require the extremely cumbersome finite element analysis techniques previously used, and therefore provide a much more rapid analytical solution procedure.
  • analytical methods do not account for such features as weld joint geometry.
  • an analytical based model may be used for providing rapid, global solutions, and the FEM may be used to provide accurate temperature models for local areas of concern.
  • the present invention is directed to overcoming one or more of the problems as set forth above .
  • a method for providing a simulation of a welding process using integrated models includes the steps of determining a model of a geometry of a set of materials to be welded, defining a set of coordinates of elements and nodes of the geometry model for a finite element analysis mesh, delivering the finite element analysis mesh coordinates to a thermal analysis model, the thermal analysis model including an analytical solution model and a finite element analysis model, and determining a thermal analysis of the welding process, the thermal analysis responsively providing a thermal history of the welding process.
  • the method further includes the steps of delivering the thermal history of the welding process to a structural analysis model, and providing a structural analysis of the welding process as a function of the thermal history.
  • Fig. 1 is a block diagram illustrating a preferred embodiment of the present invention.
  • Fig. 2 is a flow diagram illustrating a preferred method of the present invention.
  • FIG. 1 a block diagram illustrating a preferred embodiment of a set of integrated models 100 for performing a simulation analysis of a welding process is shown.
  • the integrated models 100 work together to determine stresses and distortions of a material which is welded in the welding process.
  • the stresses and distortions have an adverse effect on the strengths and characteristics of the material. Therefore, it is desired to model the stresses and distortions, and use the information from the models to determine methods which may minimize the adverse effects of welding.
  • an interconnection tool 114 such as a graphical user interface (GUI) , interconnects the models into an integrated network of working models to determine stresses and distortions of the material.
  • the interconnection tool 114 is preferably computer-based and may be configured to operate autonomously, through manual intervention, or some combination of the two modes. For example, the interconnection tool 114 may coordinate the modeling functions while displaying the status and results to a human, who may override the system or input additional information at any desired time .
  • a geometry modeler 102 determines the geometry model for the materials to be welded. Preferably, the geometry modeler 102 simplifies the geometry by removing unnecessary features of the materials from the model. Examples of such features include, but are not limited to, chamfers, holes, slight irregularities, and the like.
  • the geometry model data is then delivered to a meshing tool 104.
  • the meshing tool 104 is used to generate a finite element analysis mesh, preferably by defining coordinates for elements and nodes which constitute the mesh. Finite element analysis techniques which use mesh coordinates are well known in the art and will not be described further.
  • a thermal analysis model 106 is used to perform a thermal analysis of the materials during the welding process.
  • the thermal analysis model 106 includes at least two models.
  • An analytical solution model 108 provides a rapid analytical solution of the thermal process, i.e., welding process, for a global solution of distortions caused by the welding process.
  • a finite element analysis model 110 provides local detailed analysis of residual stress from the welding process.
  • the analytical solution model 108 determines solutions of point heat sources, the point heat sources being obtained from heat input based on welding processes and reflected heat sources determined from adiabatic boundary conditions of the material. The total analytical solution is determined from superposition of all the point heat sources.
  • the analytical solution model 108 provides a rapid solution for the complete welding process. However, the solution is not highly detailed. Therefore, the analytical solution model 108 is typically used when a fast, global solution is desired, and a high degree of detail is not needed.
  • the finite element analysis model 110 employs numerical computations of conditions at each of the desired node and element coordinates of the finite element analysis mesh. The finite element analysis model tends to be computationally lengthy and intensive. Therefore, the finite element analysis model 110 is generally used only when a detailed analysis of a specific portion of the model is desired.
  • the information from the thermal analysis model 106 is compiled into a thermal history and delivered to a structural analysis model 112.
  • the finite element mesh provided by the meshing tool 104 is delivered to the structural analysis model 112.
  • the interconnection is automatically established in the interconnection tool 114.
  • the thermal history is delivered from the thermal analysis model 106 to the structural analysis model 112 by way of an interface module 116.
  • the interface module 116 is automated from the interconnection tool 114 and is adapted to seamlessly connect the thermal solution from the analytical solution model 108, the finite element analysis model 110, or both, to the structural analysis model 112.
  • the structural analysis model 112 provides further analysis of the materials during the welding process. Typically, the behavior of the material during welding is analyzed and modeled.
  • Examples of features analyzed include, but are not limited to, melting and remelting of the material, phase transformation of the material, cyclic effects of multiple weld passes, and the like.
  • the stresses and distortions of the material are determined by the structural analysis model. Preferably, the determined stresses and distortions may be further analyzed and subsequently used to modify the welding process to reduce the adverse effects of the extreme heat associated with welding.
  • Fig. 2 a flow diagram illustrating a preferred method of the present invention.
  • a model of the geometry of a set of materials to be welded is determined.
  • a set of coordinates of elements and nodes of the geometry model is defined for a finite element analysis mesh.
  • the finite element analysis mesh coordinates are delivered to a thermal analysis model 106.
  • the thermal analysis model 106 includes an analytical solution model 108 and a finite element analysis model 110.
  • a thermal analysis of the welding process is determined as a function of at least one of the analytical solution model 108 and the finite element analysis model 110.
  • the thermal analysis preferably provides a thermal history of the welding process.
  • the thermal history of the welding process is delivered to a structural analysis model 112.
  • a structural analysis of the welding process as a function of the thermal history is provided.
  • the structural analysis includes information related to stresses and distortions caused by the welding process. This information may be used to develop methods and techniques to modify the welding process to minimize the stresses and distortions produced during subsequent welds .

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Theoretical Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Investigating Or Analyzing Materials Using Thermal Means (AREA)
  • Investigating Strength Of Materials By Application Of Mechanical Stress (AREA)

Abstract

A method and apparatus for providing a simulation of a welding process using integrated models (100) which are interconnected by an interconnection tool (114) to determine stresses and distortions of a material being welded. The method and apparatus includes determining a model of a geometry of a set of materials to be welded, defining a set of coordinates of elements and nodes of the geometry model (102) for a finite element analysis mesh, delivering the finite element analysis mesh coordinates to a thermal analysis model (106), the thermal analysis model (106) including an analytical solution model (108) and a finite element analysis model (110), and determining a thermal analysis of the welding process, the thermal analysis responsively providing a thermal history of the welding process. The method and apparatus further includes delivering the thermal history of the welding process to a structural analysis model (112), and providing a structural analysis of the welding process as a function of the thermal history.

Description

Description
METHOD AND APPARATUS FOR PROVIDING A SIMULATION OF A WELDING PROCESS USING INTEGRATED MODELS
Technical Field
This invention relates generally to a method and apparatus for modeling a welding process and, more particularly, to a method and apparatus for integrating models for a welding process to perform a thermal and structural analysis of the process.
Background Art
The process of welding materials has some amount of detrimental effect on the materials being welded. For example, materials being welded are subjected to residual stresses and distortions due to the extreme heat caused by the weld process .
In the past, attempts have been made to analyze and determine the effects of heat on materials from the welding process. One method in particular, the finite element method (FEM) , uses finite element analysis to model the weld process, and has been widely used to analyze the thermal effects of welding. However, FEM can be extremely cumbersome to implement and very costly.
Another method used to determine the effects of heat on materials from the welding process incorporates an analytical solution to determine the thermal history of the welding process. For example, analytical solutions have been developed which use the superposition of point heat source solutions. These methods generally do not require the extremely cumbersome finite element analysis techniques previously used, and therefore provide a much more rapid analytical solution procedure. However, analytical methods do not account for such features as weld joint geometry. Furthermore, it may be desired to use both types of thermal models for some applications. For example, an analytical based model may be used for providing rapid, global solutions, and the FEM may be used to provide accurate temperature models for local areas of concern.
The present invention is directed to overcoming one or more of the problems as set forth above .
Disclosure of the Invention
In one aspect of the present invention a method for providing a simulation of a welding process using integrated models is disclosed. The method includes the steps of determining a model of a geometry of a set of materials to be welded, defining a set of coordinates of elements and nodes of the geometry model for a finite element analysis mesh, delivering the finite element analysis mesh coordinates to a thermal analysis model, the thermal analysis model including an analytical solution model and a finite element analysis model, and determining a thermal analysis of the welding process, the thermal analysis responsively providing a thermal history of the welding process. The method further includes the steps of delivering the thermal history of the welding process to a structural analysis model, and providing a structural analysis of the welding process as a function of the thermal history.
Brief Description of the Drawings
Fig. 1 is a block diagram illustrating a preferred embodiment of the present invention; and
Fig. 2 is a flow diagram illustrating a preferred method of the present invention.
Best Mode for Carrying Out the Invention Referring to Fig. 1, a block diagram illustrating a preferred embodiment of a set of integrated models 100 for performing a simulation analysis of a welding process is shown. The integrated models 100 work together to determine stresses and distortions of a material which is welded in the welding process. The stresses and distortions have an adverse effect on the strengths and characteristics of the material. Therefore, it is desired to model the stresses and distortions, and use the information from the models to determine methods which may minimize the adverse effects of welding.
In the preferred embodiment, an interconnection tool 114, such as a graphical user interface (GUI) , interconnects the models into an integrated network of working models to determine stresses and distortions of the material. The interconnection tool 114 is preferably computer-based and may be configured to operate autonomously, through manual intervention, or some combination of the two modes. For example, the interconnection tool 114 may coordinate the modeling functions while displaying the status and results to a human, who may override the system or input additional information at any desired time . A geometry modeler 102 determines the geometry model for the materials to be welded. Preferably, the geometry modeler 102 simplifies the geometry by removing unnecessary features of the materials from the model. Examples of such features include, but are not limited to, chamfers, holes, slight irregularities, and the like.
The geometry model data is then delivered to a meshing tool 104. The meshing tool 104 is used to generate a finite element analysis mesh, preferably by defining coordinates for elements and nodes which constitute the mesh. Finite element analysis techniques which use mesh coordinates are well known in the art and will not be described further.
A thermal analysis model 106 is used to perform a thermal analysis of the materials during the welding process. In the preferred embodiment, the thermal analysis model 106 includes at least two models. An analytical solution model 108 provides a rapid analytical solution of the thermal process, i.e., welding process, for a global solution of distortions caused by the welding process. A finite element analysis model 110 provides local detailed analysis of residual stress from the welding process. In the preferred embodiment, the analytical solution model 108 determines solutions of point heat sources, the point heat sources being obtained from heat input based on welding processes and reflected heat sources determined from adiabatic boundary conditions of the material. The total analytical solution is determined from superposition of all the point heat sources. The principle of obtaining reflected heat sources from adiabatic boundary conditions is well known in the art and will not be discussed further. The analytical solution model 108 provides a rapid solution for the complete welding process. However, the solution is not highly detailed. Therefore, the analytical solution model 108 is typically used when a fast, global solution is desired, and a high degree of detail is not needed. The finite element analysis model 110 employs numerical computations of conditions at each of the desired node and element coordinates of the finite element analysis mesh. The finite element analysis model tends to be computationally lengthy and intensive. Therefore, the finite element analysis model 110 is generally used only when a detailed analysis of a specific portion of the model is desired.
The information from the thermal analysis model 106 is compiled into a thermal history and delivered to a structural analysis model 112. In addition, the finite element mesh provided by the meshing tool 104 is delivered to the structural analysis model 112. The interconnection is automatically established in the interconnection tool 114. In the preferred embodiment, the thermal history is delivered from the thermal analysis model 106 to the structural analysis model 112 by way of an interface module 116. Preferably, the interface module 116 is automated from the interconnection tool 114 and is adapted to seamlessly connect the thermal solution from the analytical solution model 108, the finite element analysis model 110, or both, to the structural analysis model 112. The structural analysis model 112 provides further analysis of the materials during the welding process. Typically, the behavior of the material during welding is analyzed and modeled. Examples of features analyzed include, but are not limited to, melting and remelting of the material, phase transformation of the material, cyclic effects of multiple weld passes, and the like. The stresses and distortions of the material are determined by the structural analysis model. Preferably, the determined stresses and distortions may be further analyzed and subsequently used to modify the welding process to reduce the adverse effects of the extreme heat associated with welding. Industrial Applicability
As an example of an application of the present invention, reference is made to Fig. 2, a flow diagram illustrating a preferred method of the present invention.
In a first control block 202, a model of the geometry of a set of materials to be welded is determined. In a second control block 204, a set of coordinates of elements and nodes of the geometry model is defined for a finite element analysis mesh. In a third control block 206, the finite element analysis mesh coordinates are delivered to a thermal analysis model 106. In the preferred embodiment, the thermal analysis model 106 includes an analytical solution model 108 and a finite element analysis model 110.
In a fourth control block 208, a thermal analysis of the welding process is determined as a function of at least one of the analytical solution model 108 and the finite element analysis model 110. The thermal analysis preferably provides a thermal history of the welding process. In a fifth control block 210, the thermal history of the welding process is delivered to a structural analysis model 112. In a sixth control block 212, a structural analysis of the welding process as a function of the thermal history is provided. Preferably, the structural analysis includes information related to stresses and distortions caused by the welding process. This information may be used to develop methods and techniques to modify the welding process to minimize the stresses and distortions produced during subsequent welds .
Other aspects, objects, and features of the present invention can be obtained from a study of the drawings, the disclosure, and the appended claims.

Claims

Claims
1. A method for providing a simulation of a welding process using integrated models (100) , the integrated models (100) being interconnected by an interconnection tool (114) to determine stresses and distortions of a material being welded, including the steps of : determining a model of a geometry of the material; defining a set of coordinates of elements and nodes of the geometry model (102) for a finite element analysis mesh; delivering the finite element analysis mesh coordinates to a thermal analysis model (106) , the thermal analysis model (100) including an analytical solution model (108) and a finite element analysis model (110) ; determining a thermal analysis of the welding process as a function of at least one of the analytical solution model (108) and the finite element analysis model (110) , the analytical solution model (108) being adapted to provide a thermal history of the welding process for a global distortion analysis, and the finite element analysis model (110) being adapted to provide a thermal history of the welding process for a detailed residual stress analysis; delivering the thermal history of the welding process to a structural analysis model (112); and providing a structural analysis of the welding process as a function of the thermal history.
2. A method, as set forth in claim 1, wherein providing a thermal history of the welding process for a detailed residual stress analysis includes the step of providing a thermal history of the welding process for a specific portion of the welding process .
3. A method, as set forth in claim 1, wherein providing a structural analysis of the welding process includes the step of modeling a set of characteristics of the materials being welded during the welding process.
4. A method, as set forth in claim 3, wherein characteristics of the materials include residual stresses and distortions.
5. A method, as set forth in claim 1, wherein determining a thermal analysis of the welding process as a function of the analytical solution model
(108) includes the steps of: determining a set of adiabatic boundary conditions of the material being welded; determining a set of reflected heat sources as a function of the adiabatic boundary conditions; determining a set of point heat sources as a function of the reflected heat sources; and determining a total analytical solution from superposition of the point heat sources.
6. A method, as set forth in claim 1, wherein determining a thermal analysis of the welding process as a function of the finite element analysis model (110) includes the step of determining a set of numerical computations of conditions at each desired node and element coordinate of the finite element analysis mesh.
7. A method, as set forth in claim 1, wherein delivering the thermal history of the welding process to a structural analysis model (112) includes the step of delivering the thermal history by way of an interface module (116) .
8. An apparatus for providing a simulation of a welding process using integrated models (100), the integrated models (100) being interconnected by an interconnection tool (114) to determine stresses and distortions of a material being welded, comprising: a geometry modeler (102) adapted to determine a model of a geometry of the material; a meshing tool (104) adapted to define a set of coordinates of elements and nodes of the geometry model (102) for a finite element analysis mesh; a thermal analysis model (106) adapted to receive the finite element analysis mesh, determine a thermal analysis of the welding process, and responsively provide a thermal history of the welding process, wherein the thermal analysis model (106) includes : an analytical solution model (108) adapted to provide a thermal history of the welding process for a global distortion analysis; and a finite element analysis model (110) adapted to provide a thermal history of the welding process for a detailed residual stress analysis; and a structural analysis model (112) adapted to provide a structural analysis of the welding process as a function of the thermal history.
9. An apparatus, as set forth in claim 8, wherein the interconnection tool (114) is a graphical user interface .
PCT/US2000/025958 1999-10-27 2000-09-21 Method and apparatus for providing a simulation of a welding process using integrated models WO2001030532A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
CA002384010A CA2384010A1 (en) 1999-10-27 2000-09-21 Method and apparatus for providing a simulation of a welding process using integrated models
EP00963707A EP1242211A1 (en) 1999-10-27 2000-09-21 Method and apparatus for providing a simulation of a welding process using integrated models
JP2001532927A JP2003512180A (en) 1999-10-27 2000-09-21 Method and apparatus for simulating a welding process using an integrated model

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US16181699P 1999-10-27 1999-10-27
US60/161,816 1999-10-27

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WO (1) WO2001030532A1 (en)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2401699A (en) * 2001-12-20 2004-11-17 Caterpillar Inc A method of manufacturing a load bearing member and determining the effects of heat caused by welding
WO2005027002A1 (en) * 2003-09-12 2005-03-24 Volvo Aero Corporation Optimisation of sequential combinatorial processes
US7165929B2 (en) 2001-12-20 2007-01-23 Caterpillar Inc Load bearing member arrangement and method
CN102152016A (en) * 2010-02-03 2011-08-17 株式会社日立制作所 Method for simulation of welding distortion
CN103008827A (en) * 2012-12-05 2013-04-03 天津大学 Systematic analysis method applied to welding physical field coupling in water environments
CN103273207A (en) * 2013-04-12 2013-09-04 广东工业大学 Press machine body welding deformation eliminating method based on residual stress quantitative analysis
CN104820781A (en) * 2015-05-06 2015-08-05 北京航空航天大学 Prediction method of thermal fatigue life of BGA (Ball Grid Array) welding spot considering influence of sequential temperature cycling load loading
US9606527B2 (en) 2014-06-30 2017-03-28 Caterpillar Inc. Automated fabrication system implementing 3-D void modeling

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EP1762952A4 (en) 2004-03-29 2012-11-07 Univ Osaka Welding deformation computing method, welding deformation computing device, computer program, and recording medium
CN101633073B (en) * 2009-08-21 2011-03-30 长沙金阳机械设备科技开发有限公司 Process for welding automobile crane subsidiary arm connecting support seat

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D. ISCHENKO AND R.N. IBRAHIM: "Development of new welding pattern in order to minimise distorsions in marine structure", KEY ENGINEERING MATERIALS, vol. 145-149, 1998, pages 859 - 864, XP000944978 *

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2401699A (en) * 2001-12-20 2004-11-17 Caterpillar Inc A method of manufacturing a load bearing member and determining the effects of heat caused by welding
GB2401699B (en) * 2001-12-20 2005-05-25 Caterpillar Inc Load bearing member arrangement and method
US7165929B2 (en) 2001-12-20 2007-01-23 Caterpillar Inc Load bearing member arrangement and method
WO2005027002A1 (en) * 2003-09-12 2005-03-24 Volvo Aero Corporation Optimisation of sequential combinatorial processes
US7991593B2 (en) 2003-09-12 2011-08-02 Volvo Aero Corporation Optimisation of sequential combinatorial process
CN102152016A (en) * 2010-02-03 2011-08-17 株式会社日立制作所 Method for simulation of welding distortion
CN103008827A (en) * 2012-12-05 2013-04-03 天津大学 Systematic analysis method applied to welding physical field coupling in water environments
CN103008827B (en) * 2012-12-05 2015-06-17 天津大学 Systematic analysis method applied to welding physical field coupling in water environments
CN103273207A (en) * 2013-04-12 2013-09-04 广东工业大学 Press machine body welding deformation eliminating method based on residual stress quantitative analysis
US9606527B2 (en) 2014-06-30 2017-03-28 Caterpillar Inc. Automated fabrication system implementing 3-D void modeling
CN104820781A (en) * 2015-05-06 2015-08-05 北京航空航天大学 Prediction method of thermal fatigue life of BGA (Ball Grid Array) welding spot considering influence of sequential temperature cycling load loading
CN104820781B (en) * 2015-05-06 2017-09-29 北京航空航天大学 Consider that temperature follows the BGA thermal fatigue life of solder joint Forecasting Methodologies of load sequence loading effect

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CA2384010A1 (en) 2001-05-03
EP1242211A1 (en) 2002-09-25

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