Üç boyutlu ve iki boyutlu eleman tiplerinin punta kaynaklı bileşenlerin gerilme ve ömür analizleri üzerindeki etkisi

Öz

Sonlu eleman analizleri ve bilgisayar destekli mühendislik yöntemleri günümüz araştırma-geliştirme projelerinde anahtar role sahiptir. Model tipine göre eleman seçimi simülasyon doğruluğu için azami önem arz etmekte iken, bazı durumlarda geometrik koşullar araştırmacılar için bu seçimi zorlaştırabilmektedir. Bu makalenin amacı punta kaynaklı bileşenler için üç boyutlu kübik ve iki boyutlu dörtgen elemanlar kullanılması durumunda oluşan farklılıklar hakkında bilgi sunmaktır. Çalışma kapsamında iki puntalı kayma numuneleri farklı eleman tipleri ile modellenerek gerilme analizleri ve üç farklı dinamik yük koşulunda yüksek döngü yorulma simülasyonları gerçekleştirilmiştir. Analizler neticesinde deplasman, gerilme değerleri ve tensörleri, yüksek döngü bileşen ömürleri incelenmiş ve iki farklı eleman tipi ile oluşturulan modeller arasındaki ayrımlar raporlanmıştır. Simülasyon sonucunda elde edilen ömür değerleri, yüksek döngü yorulma test verileri ile karşılaştırılarak farklı tip elemanlar için doğruluk derecelendirme çalışmaları tamamlanmıştır. Makale kapsamında gerçekleştirilen çalışmalar neticesinde kaynak bölgesinde rijit elemanlar ile eşleştirilen iki boyutlu dörtgen eleman modelleme yönteminin, üç boyutlu kübik eleman ile modellemeye nazaran yorulma testleri ile daha uyumlu sonuçlar verdiği gözlemlenmiştir. Havacılık, otomotiv ve deniz sektöründe fazlaca uygulanan punta kaynak yönteminin yüksek döngü yorulma testleri ile doğrulanmış sonlu eleman analizlerinin modelleme prosedürü de çalışmada detaylandırılmıştır.

Anahtar Kelimeler

• Punta kaynak
• Sonlu elemanlar analiz
• Gerilme analizi
• Yüksek döngü yorulma

Effect of 3 dimensional and 2 dimensional element types on stress and life analysis of spot-welded components

Abstract

Finite element analysis and computer-aided engineering methods have an essential role in modern research and development projects. Although proper element selection for the modeling type is critical for the accuracy of simulations, the selection process might be difficult for researchers in some cases where geometric conditions are challenging. The main objective of this paper is to present the differences in simulation results when three-dimensional cubic and two-dimensional quadrilateral elements are used for the modeling of spot-welded components. Following the modeling of shear specimens having two spot welds with different element types, static analysis, and high cycle fatigue simulations at three different dynamic load cases have been run within the context of this study. Displacement, stress values and tensors, as well as high cycle fatigue life have been evaluated as the output of analysis, and deviations due to different element types have been reported. Accuracy levels of different element types have been determined by comparing the life obtained by simulations with high cycle fatigue tests. The studies conducted within the content of this paper indicate that the rigid spot weld modeling with two dimensional quadrilateral elements give better consistency with the fatigue tests in comparison with the modeling with three dimensional cubical elements. The modeling procedures of correlated high cycle fatigue simulations have been detailed for spot welding, which is one of the most applied methods in aviation, automotive and marine industry.

Keywords

• Spot weld
• Finite element analysis
• Stress analysis
• High cycle fatigue

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