Control de la Calidad de la Construccin

Naval Utilizando Simulacin por medio de

Elementos Finitos

Dr. Adn Vega Senz

Laboratorio Especializado en Procesos de Unin y Manufactura

Facultad de Ingeniera Mecnica Universidad Tecnolgica de Panam
 Contenido

Introduccin
Deformaciones inducidas por el calor
Mtodos para predecir deformaciones
El mtodo de deformacin Inherente
Casos estudiados
conclusiones
 INTRODUCCION

Minimisation of ship panel thickness to increase

vessel speed - 4 mm thickness desired
Reduction in thickness leads to severely large
welding distortions
high rectification or re-manufacture costs
Methods to predict weld distortion are required
Understand of the key factors causing
distortion
 Weld-induced
distortion

Additional costs for rework caused by weld-induced distortion: $3Mio/ship

 Welding distortion is caused by highly non-uniform temperature
distribution in the welded region
welding distortion is mainly dependant on
Material
Maximum temperature
Degree of restraints,

- DOR is determined by
Plate thickness
Welding type
Butt or fillet welding
Welding conditions
longitudinal shrinkage transverse shrinkage bending

angular distortion rotational distortion buckling

Weld Distortion Modes

7
METHOD FOR PREDICTION OF WELDING
DISTORTION

Simplified Load

3D Thermal elastic plastic FEM

Elastic FEM (inherent strain method)

Welding deformation prediction
Simplified load method
Simple rule-of-thumb based on previous production data
Only applicable to existing cases
Cannot predict transient shape change
3-Dimensional thermo-elasto-plastic FEA
Computationally expensive
Can predict transient shape, temperature, stress/strain
distribution change
Numerical simulation method (Inherent strain method)
Assumption of inherent strain distribution
Cannot predict transient shape change
Inherent Strain Method
Compared to 3D FEA result
~1/500 computation time

Relatively high accuracy

Longer weld line results in

higher accuracy
Inherent Strain Method

Originally developed to predict residual stress within structure [Ueda, 1975]

Hybrid method (partially analytic, partially experimental)
Inelastic and non-compatible strain that accounts for plastic deformation of
the body
Defined as
dS 2 dS 0
*
dS 0
 How to use the inherent strain method?
Step 1. Extracting inherent strain using thermal-elastic-
plastic FEM
x

Step 2. Develop a inherent strain database for

each material and each welding process
Database of inherent strain
Step 3. Introduce the components of inherent
strain, from database, in the heating area as a
load

Step 4. Perform Elastic analysis

 6.0
0 200 400 600 800 10 00 12 00 1 4 00

Deflection [mm] 5.0 5

4.0 4

3.0 3

2.0 2

Elastic FEM
1.0 Thermal Elastic-plastic FEM 1

0.0 0

0 200 400 600 800 1000 1200 1400

L [mm]

Transverse direction
 6.0
0 20 0 40 0 6 00 800 1 000 12 0 0 1 4 00

5.0 5
Deflection [mm]

4.0 4

3.0 Elastic FEM 3

Thermal Elastic-plastic FEM

2.0 2

1.0 1

0.0 0

0 200 400 600 800 1000 1200 1400

L [mm]
Longitudinal direction
Improved Inherent Strain Method

Step 1: Predict the four components of inherent

strain at the central region of the plate.

Step 2: Predict the four components of inherent

strain at plate edges.

Step 3: Make correction to the values obtained in

Step-1 and 2 for location of welding and plate size.
 Step 4: Based on the sequence of welding,
identify if multi-passes, parallel welding and/or
crossed welding are needed. Then, obtain the
correction values from databases.

Step 5: Introduce the correction values obtained

in Step-4 into the values of inherent strain
predicted in Step-1 to Step-3.
Step 6: Introduce the inherent strain obtained in
Step-5 into the elastic FEM model.

Step 7: Repeat Step-1 to 6 for each additional

welding pass.

Step 8: Perform elastic FE analysis.

EXAMPLES OF STUDIED CASES
Ships structures
block assembly
block assembly

Block
division
 Early stage of block assembly

Middle stage of block

assembly

Bending deformation of
ship hull
 Conclusiones

Inherent strain method is well applied to the prediction

of welding distortion since it captures the core
mechanism of welding distortion generation

Inherent strain method is an effective method for

prediction of welding distortion due to the fact that just a
short time is needed in order to obtain the results

The improved inherent strain method here proposed is

an important tool because reduce the error associated to
the inherent strain method

An inherent deformation database is needed in order to

use the inherent strain method
Muchas Gracias por su Atencin