[KSCI] Korea Science Citation Index Service

http://dx.doi.org/10.1016/j.ijnaoe.2018.10.001

Variation simulation and diagnosis considering in-plane/out-of-plane welding distortion

Lee, Hyeonkyeong (Department of Mechanical Engineering, KAIST)
Chung, Hyun (Department of Naval Architecture & Ocean Engineering, Chungnam National University)

Publication Information

International Journal of Naval Architecture and Ocean Engineering / v.11, no.1, 2019 , pp. 553-571 More about this Journal

Abstract

Geometric variation including welding distortion accumulates as many parts are joined together, ultimately affecting the final product. This variation is then subjected to correction, which requires considerable effort, time, and cost. This variation can be categorized as in-plane/out-of-plane variation. To date, studies on variation simulation have largely focused on the out-of-plane variation, however the variation generated in the in-plane direction requires more time and efforts to correct afterwards. This research aims to construct a variation simulation model considering both the in-plane and out-of-plane variations. A geometric analysis was performed to derive an equation that reflects the coupling effect of the out-of-plane variation on the in-plane variation. The proposed model is validated with case study analysis and the results shows that good fidelity in predicting and diagnosing the in-plane variation during the block assembly process considering welding distortion.

Keywords

Ship block assembly; Welding distortion; Compliant assembly; Variation simulation; In-plane variation; Process diagnosis;

Citations & Related Records

Reference

1	Chase, K.W., Magleby, S.P., Gao, J., 1996b. Tolerance Analysis of 2-D and 3-D Mechanical Assemblies with Small Kinematic Adjustment. http://adcats.et.byu.edu/home.php.
2	Chase, K.W., Magleby, S.P., Glancy, C.G., 1998. A comprehensive system for computer-aided tolerance analysis of 2-D and 3-D mechanical assemblies. In: Geometric Design Tolerancing: Theories, Standards and Applications. Springer, Boston, MA, pp. 294-307.
3	Clement, A., Riviere, A., Serre, P., Valade, C., 1998. The TTRSs: 13 constraints for dimensioning and tolerancing. In: ElMaraghy, H.A. (Ed.), Geometric Design Tolerancing: Theories, Standards and Applications. Chapman & Hall, London, pp. 123-131.
4	Camelio, J.A., Hu, S.J., Yim, H., 2003. Sensor Placement for effective diagnosis of multiple faults in fixturing of compliant parts. J. Am. Soc. Mech. Eng. 373-380.
5	Camelio, J.A., Hu, S.J., 2004. Multiple fault diagnosis for sheet metal fixtures using designated component analysis. J. Manuf. Sci. Eng. 126 (1), 91. DOI
6	Ceglarek, D., Shi, J., 1995. Dimensional variation reduction for automotive body assembly. Manuf. Rev. 8 (2).
7	Cheng, W.T., 2005. In Plane Shrinkage Strains and Their Effects on Welding Distortion in Thin Wall Structures. The Ohio State University.
8	Chung, H., 2006. Tolerance Analysis of Compliant Metal Plate Assemblies Considering Welding Distortion. Ph.D. Thesis. The University of Michigan, USA.
9	Desrochers, A., Riviere, A., 1997. A matrix approach to the representation of tolerance zones and clearances. Int. J. Adv. Manuf. Technol. 13, 630-636. https://doi.org/10.1007/BF01350821. DOI
10	Desrochers, A., 1999. Modeling three dimensional tolerance zones using screw parameters. In: Proceedings DETC 25th Design Automation Conference, September 12-15, Las Vegas, DETC99/DAC-8587.
11	Lee, J., 2016. Tolerance Analysis and Diagnosis Model of Compliant Block Assembly Considering Welding Deformation. World Maritime Technology Conference.
12	Liu, S.C., Hu, S.J., 1997. Variation simulation for deformable sheet metal assemblies using finite element methods. J. Manuf. Sci. Eng. 119, 368-374. DOI
13	Liu, Y.G., Hu, S.J., 2005. Assembly fixture fault diagnosis using designated component analysis. J. Manuf. Sci. Eng. 127 (2), 358-368. DOI
14	Luo, Y., Murakawa, H., Ueda, Y., 1997. Prediction of welding deformation and residual stress by elastic FEM based on inherent strain (Report I): mechanism of inherent strain production (mechanics, strength & structure design). J. Trans. JWRI 26 (2), 49-57.
15	Michaleris, P., DeBiccari, A., 1997. Prediction of welding distortion. Weld. J. 76 (4), S172-S181.
16	Mandal, N.R., Sundar, C.V.N., 1997. Analysis of welding shrinkage. J. Weld. Res. Suppl. 233s-2377s.
17	Spicknall, M.H., Kumar, R., 2003. Development of dimensional variation simulation and analysis tool for the shipbuilding industry. J. Ship Prod. 19 (4), 207-216. DOI
18	Marziale, M., Polini, W., 2009. A review of two models for tolerance analysis of an assembly: vector loop and matrix. Int. J. Adv. Manuf. Technol. 43, 1106-1123. https://doi.org/10.1007/s00170-008-1790-0. DOI
19	Salomons, O.W., Haalboom, F.J., Jonge Poerink, H.J., van Slooten, F., van Houten, F.J.A.M., Kals, H.J.J., 1996. A computer aided tolerancing tool II: tolerance analysis. Comput. Ind. 31, 175-186. https://doi.org/10.1016/0166-3615(96)00047-4. DOI
20	Spicknall, M.H., Kumar, R., 2002. A dimensional engineering process for shipbuilding. J. Ship Prod. 18 (2), 105-115.
21	Ha, Y.S., Cho, S.H., Jang, T.W., 2008. Development of welding distortion analysis method using residual strain as boundary condition. Mater. Sci. Forum 580-582, 649-654.
22	Chase, K.W., Gao, J., Magleby, S.P., 1995. General 2-D tolerance analysis of mechanical assemblies with small kinematic adjustments. J. Des. Manuf. 5 (4), 263-274. DOI
23	Chase, K.W., Gao, J., Magleby, S.P., Sorensen, C.D., 1996a. Including geometric feature variations in tolerance analysis of mechanical assemblies. IIE Trans. 28 (10), 795-807. DOI
24	Diego, P., 2016. Simplified Distortion Analysis for Multi-passWelding Using Layered Shell Elements Base on Inherent Strain. Master's Thesis. Korea Advanced Institute of Science and Technology, Daejeon, Republic of Korea.
25	Faerber, P.J., 1999. Tolerance Analysis of Assemblies Using Kinematically Derived Sensitivities. ADCATS Report. No. 99-3. http://adcats.et.byu.edu/home.php.
26	Hu, S.J., Wu, S.M., 1992. Identifying root causes of variation in automobile body assembly using principal component analysis. Trans. NAMRI/SME 20, 311-316.
27	Heo, H., Chung, H., 2014. Stochastic assessment considering process variation for impact of welding shrinkage on cost of ship production. Int. J. Prod. Res. 52 (20), 6076-6091. DOI
28	Jung, G.H., Tsai, C.L., 2004. Plasticity-based distortion analysis for fillet welded thin-plate T-joints - a new relationship between cumulative plastic strains and angular distortion was found. Weld. J. 83 (6), 177S-187S.
29	Kim, M.G., 2014. Simplified Welding Distortion Analysis for T-joints Fillet Welding Using Composite Shell Elements. Master's Thesis. Korea Advanced Institute of Science and Technology, Daejeon, Republic of Korea.
30	Kim, H.J., 2016. Optimal Measurement Points Decision and Welding Process Diagnosis Considering Welding Distortion. Master's Thesis. Korea Advanced Institute of Science and Technology, Daejeon, Republic of Korea.
31	Yuan, M.G., Ueda, Y., 1996. Prediction of residual stresses in welded T- and I-joints using inherent strains. J. Eng. Mater. Technol. Trans. ASME 118 (2), 229-234. DOI
32	Storch, R.L., 1985. Accuracy control variation-merging equations: a case study of their application in u.s. shipyards. J. Ship Prod. 1 (2), 133-144. DOI
33	Shibahara, M., Murakawa, H., 1998. Effect of various factors on transverse shrinkage under butt welding. Trans. JWRI 27 (2) pp97-106.
34	Liu, S.C., Hu, S.J., 1995. An offset finite element model and its applications in predicting sheet metal assembly variation. Int. J. Mach. Tool Manufact. 35 (11), 1545-1557. DOI
35	Takezawa, N., 1980. An improved method for establishing the process wise quality standard, union of japanese scientists and engineers (JUSE), 27 (3), 63-76.
36	Ueda, Y., Yuan, M.G., 1993. Prediction of residual-stresses in butt welded plates using inherent strains. J. Eng. Mater. Technol. Trans. ASME 115 (4), 417-423. DOI