Determination of Distortions by Finite Element Analysis Using the Goldak Model in a Welded Joint Structure

Year 2023, , 53 - 64, 31.12.2023

Barış Gökçe , Osman Bahadır Özden

https://doi.org/10.47112/neufmbd.2023.9

Abstract

This study deals with the combined use of thermal analysis and structural analysis methods used in finite element analysis (FEA) and the determination of distortion and residual stress with the Goldak model. Distortion refers to the change in the way a material deforms or bends under the application of heat or mechanical load. Controlling distortion is of great importance in many applications, especially in the manufacturing and assembly of sensitive parts. Residual stresses reduce the fatigue life of the structure and affect its structural safety. At the beginning of this study, thermal analyzes were performed for four different welding paths in a complex structure. Ansys software was used as SEA software and Goldak double ellipsoid model was defined with Ansys programming design language (APDL). The data from the analysis are used to understand the heating and cooling behavior of the material. Then, thermal analysis results were combined with structural analysis and an evaluation was made to determine the causes and effects of distortion as well as residual stress. After the structural analysis, the stresses and deformations caused by the loads on the structure due to the heat were investigated. As a result of the study, the residual stress in a complex structure of a mobile crane was found to be 243.56 MPa, and the distortion after welding was 0.56 mm in the X direction, 0.83 mm in the Y axis and 0.37 mm in the Z axis. With these findings and approaches, approaches are presented to prevent or minimize distortion in the manufacturing and assembly processes of sensitive parts.

Keywords

Welded Joints, Thermal Analysis, Heat Effect

Kaynaklı Bağlantıya Sahip Karmaşık Bir Yapıda Goldak Modeli Kullanılarak Distorsiyonların ve Kalıntı Gerilmelerin Nümerik Analizler ile Belirlenmesi

Abstract

Bu çalışma, sonlu elemanlar analizlerinde (SEA) kullanılan termal analiz ve yapısal analiz yöntemlerinin birleşik kullanımı ve Goldak modeli ile distorsiyonun ve kalıntı gerilmenin tespit edilmesini ele almaktadır. Distorsiyon, bir malzemenin ısı uygulaması veya mekanik yük altında deformasyon veya bükülme şeklindeki değişimini ifade eder. Distorsiyonun kontrol edilmesi, özellikle hassas parçaların üretimi ve montajı süreçlerinde birçok uygulamada büyük önem taşımaktadır. Kalıntı gerilmelerde yapının özellikle yorulma ömrünü azaltmakta olup yapısal olarak emniyetini etkilemektedir. Bu çalışmanın başlangıcında, karmaşık bir yapıda dört farklı kaynak yolu için termal analizler gerçekleştirilmiştir. SEA yazılımı olarak Ansys yazılımı kullanılmış olup Goldak çift elipsoit modeli Ansys programlama tasarım dili (APDL) ile tanımlanmıştır. Analizden elde edilen veriler, malzemenin ısınma ve soğuma davranışını anlamak için kullanılmıştır. Ardından, termal analiz sonuçları yapısal analiz ile birleştirilerek distorsiyonun nedenlerini ve etkileri ile birlikte kalıntı gerilmenin tespiti için bir değerlendirme yapılmıştır. Yapısal analiz sonrasında, yapı üzerinde ısıdan dolayı oluşan yüklerin neden olduğu gerilmeler ve deformasyonlar incelenmiştir. Çalışma sonucunda, mobil bir vince ait karmaşık bir yapıda kalıntı gerilme 243.56 MPa, kaynak tamamlandıktan sonra oluşan distorsiyon ise X yönünde 0.56mm, Y ekseninde 0.83 mm ve Z ekseninde 0.37 mm tespit edilmiştir. Bu bulgular ve yaklaşımlar ile hassas parçaların üretimi ve montajı süreçlerinde distorsiyonun önlenmesi veya minimize edilmesi için yaklaşımlar sunulmuştur.

Keywords

Kaynaklı Bağlantılar, Termal Analiz, Isı Etkisi, Distorsiyon

Supporting Institution

MPG MAKİNE PRODÜKSİYON GRUBU MAKİNE İMALAT SANAYİ VE TİCARET A.Ş.

Thanks

MPG MAKİNE PRODÜKSİYON GRUBU MAKİNE İMALAT SANAYİ VE TİCARET A.Ş.

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