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Industrial Technology Institute, Hyundai Heavy Industries Co. Ltd., Ulsan, South Korea
a
Abstract
The purpose of this study is to establish the control methods
for the out-of-plane distortion of SA butt welded thin plate
during manufacturing process. In this study, the control
methods are the mechanical tensioning method for the
buckling distortion and the simple restraint method for the
angular distortion. According to the experimental results,
when the weldment was stretched in the welding direction
by the mechanical tensioning method, the amount of the
buckling distortion was sharply reduced but the angular
distortion remains after welding. However, with the
tensioning and the simple restraint method simultaneously,
all out-of-plane distortions were almost perfectly controlled.
Keywords: Out-of-plane Welding Distortion, Mechanical
Tensioning, Simple Restraint, Distortion Control Method,
Buckling Distortion, SA Butt Welded Thin Plate
1. Introduction
In SA butt weld with thin plate, the excessive out-of-plane
distortion such as angular distortion and buckling distortion
during the manufacturing process was introduced the
problems on not only the production cost but also the
structural integrity. Especially, once the buckling distortion
occurred, it is very difficult to correct the buckling
distortion having the complicated distortion mode.
According to the results of recent studies, it was found that
principal process producing the excessive buckling
distortion at thin panel welded structure was mainly
attributed to the imperfection caused by butt welding of base
plate, which was the 1st welding process for constructing the
hull structure. It means that a proper control method for
buckling distortion in SA butt weld should be first settled to
control effectively the excessive welding distortion of thin
panel welded structure. However, although the amount of
angular distortion in SA butt weld is smaller than that of the
buckling distortion, it should be also controlled to reduce
correction cost.
The purpose of this study is to establish the control methods
for the out-of-plane distortion in SA butt weld of thin plate
during the manufacturing process. In this study, the
67th Annual Assembly & International Conference of the International Institute of Welding
13-18 July 2014, Seoul, Korea
Fixed
Tension Load
Max. 340MPa
Test Piece
W
Weld
L
Max. 225MPa
Solid Element
Symmetric
Condition
Shell Element
Welding
process
SAW, SW101
electrode dia.
(1.6)
Dimensions
[WxLxt, mm]
Heat input
[cal/mm]
Tension load,
SFL [ton]
750x1,500x
4.5
190
0.0 ~
8.0xSFw
Analysis Results
Figure 2 shows the analysis results of temperature
distribution during welding and cooling. As shown in Figure
2, the maximum temperature of weld zone during welding is
1,619oC. When the plate has cooled down to room
temperature, the temperature is about 20 oC. Figure 3 shows
the distribution of longitudinal residual stress with or
without tension load of 1.5xSFw. As shown in Figure 3 the
amount of maximum residual stress with tension load
corresponding to 1.5xSFw decreased from 340MPa to
225MPa. The reduction ratio of maximum longitudinal
residual stress is about 33.8% with the tension load of
1.5xSFw.
0.4
0.0
-0.4
-0.8
Welding Only
1.5xSFw: 18.5MPa
4.0xSFw: 48.5MPa
6.0xSFw: 73.0MPa
8.0xSFw: 97.5MPa
-1.2
-1.6
-2.0
0.0
20.0
40.0
60.0
80.0
100.0
Welding Only
1.5xSFw: 18.5MPa
4.0xSFw: 48.5MPa
6.0xSFw: 73.0MPa
8.0xSFw: 97.5MPa
300.0
200.0
100.0
0.0
-100.0
-200.0
0.0
100.0
200.0
300.0
400.0
67th Annual Assembly & International Conference of the International Institute of Welding
13-18 July 2014, Seoul, Korea
0.0
1.2
20.0
40.0
60.0
80.0
SW101, 1.6
100.0
120.0
1.0
0.8
0.4
Fixture
Weld Line
0.2
SFL
0.0
0.0
2.0
4.0
6.0
8.0
Strain Gague
Data Acquisition
System
10.0
SFL/SFw
Hydraulic
Pump
Heat input
[cal/mm]
750x1,500x
4.5, 6.0
380 ~ 500
Tension load,
SFL [ton]
0.0
1.0xSFw
1.5xSFw
1.0 x SFw
Strain Gage No.1
Strain Gage No.2
1.80
During Welding
After Welding
1.60
1.40
Gage No.1
1.20
0.0
400.0
800.0
1200.0
Gage No.2
1600.0
2000.0
Time [sec]
(a) 1.0xSFw
2.60
1.5 x SFw
Strain Gage No.1
Strain Gage No.2
2.40
During Welding
After Welding
2.20
2.00
Gage No.1
1.80
0.0
Experimental Results
Figure 7 shows the verification of the longitudinal strain
under the tension load of 1.0xSFw and 1.5xSFw during the
Dimensions
[WxLxt, mm]
2.00
Tensioner
(Hydraulically Controlled Pulling Jack)
400.0
800.0
1200.0
Gage No.2
1600.0
2000.0
Time [sec]
(b) 1.5xSFw
Fig. 7 Verification of the longitudinal strain under the
tension load during the welding and cooling
67th Annual Assembly & International Conference of the International Institute of Welding
13-18 July 2014, Seoul, Korea
Non-symmetric
Test Piece
W
Weld
L
Weld
Test Piece
input
Dimensions
[WxLxt]
3,080x
8,800x
5.0mm
425
cal/mm
Analysis Results
Figure 9 shows comparison result of the angular distortion
between symmetric and non-symmetric model. In case of
non-symmetric model, excessive angular distortion of
45mm occurred at the free edge of 650mm away from the
weld line. But, the maximum angular distortion of
symmetric model was controlled below 4.5mm due to the
self-weight of the plate. However, the amount of angular
distortion in non-symmetric SA butt weld found in the free
edge exceeds about 25.4mm. The results indicate that the
angular distortion of SA butt weld having low self-restraint
should be controlled for the accuracy management. Figure
10 shows the deformed profile in non-symmetric SA butt
welds with or without restraint method. As shown in Figure
10, excessive angular distortion of 25.4mm in as-welded
state decreased to 5.4mm by applying simple restraint to the
free edge of non-symmetric model. It means that simple
restraint method is an effective method for the control of
excessive angular distortion at SA butt weld plate with nonsymmetric shape.
Max. 24.1mm
x
With
tension
load
Max. 11.0mm
(a) 1.0xSFw
Plate thickness: 6.0mm
Max. 2.0mm
(b) 1.5xSFw
Plate thickness: 4.5mm
Max. 4.5mm
(a) Symmetric
Z
Max. 25.4mm
(b) Non-symmetric
Fig. 9 Comparison result of angular distortion between
symmetric and non-symmetric model.
67th Annual Assembly & International Conference of the International Institute of Welding
13-18 July 2014, Seoul, Korea
Dimensions and
schematic shape
[WxLxt, mm]
Max. 25.4mm
x
20.0
Location
2,600x
5,000x
4.5
Test Piece
W
Weld
L
10.0
Max. 5.2mm
0.0
.
0.0
500.0
1000.0
1500.0
2000.0
2500.0
3000.0
Location [mm]
Fig. 10 Comparison result of deformed shapes of nonsymmetric with or without simple restraint
1.04
1.06
1.02
1.00
0.98
0.96
0.94
Strain Gage
During Welding
After Welding
0.92
0.0
1000.0
2000.0
3000.0
Time [sec]
Mechanical
tensioning method:
buckling distortion
control
SFL
Welding process
and heat input
Loading
conditions
380cal/mm
No tension,
With tension of 20.6tons (1.5xSFw)
67th Annual Assembly & International Conference of the International Institute of Welding
13-18 July 2014, Seoul, Korea
Max. 50mm
Max. 45mm
SFL
426cal/mm
No tension,
With tension of 31.7tons (1.5xSFw),
With tension load and simple restraint
3,300x
5,650x
5.0
Weld
Test Piece
L
5. Conclusions
In order to establish the control methods for the excessive
out-of-plane distortion in SA butt weld of thin plate, the
extensive FEA and experiments have been performed. The
main results are summarized as follows.
1. According to the FEA results, the tensile residual stress at
the butt weld sharply decreased with an increase in tension
load. Therefore, when the amount of tension load exceeding
1.5 times of longitudinal welding shrinkage force is applied
to the weld, the amount of longitudinal residual stress
decreased below the critical value inducing the buckling
distortion at the SA butt weld.
2. According to the experimental results, when the
weldment was stretched in the welding direction by the
mechanical tensioning method, the amount of the buckling
distortion was sharply reduced but the angular distortion
remains after welding. However, with the tensioning method
and the simple restraint method applied simultaneously, the
excessive out-of-plane welding distortion was almost
67th Annual Assembly & International Conference of the International Institute of Welding
13-18 July 2014, Seoul, Korea
perfectly controlled.
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