• Journal of the Society of Naval Architects of Korea
• /
• v.43 no.1 s.145
• /
• pp.68-74
• /
• 2006

The welding distortion of a hull structure in the shipbuilding industry is inevitable at each assembly stage. This geometric inaccuracy caused by the welding distortion tends to preclude the introduction of automation and mechanization and needs the additional man-hours for the adjusting work at the following assembly stage. To overcome this problem, a distortion control method should be applied. For this purpose, it is necessary to develop an accurate prediction method which can explicitly account for the influence of various factors on the welding distortion. The validity of the prediction method must be also clarified through experiments. For the purpose of reducing the weld-induced bending deflection, this paper proposes the mechanical tensioning method (MTM) as the optimum distortion control method. The validity of this method has been substantiated by a number of numerical simulations and actual measurements.

• Proceedings of the KWS Conference
• /
• 2002.10a
• /
• pp.681-687
• /
• 2002

The cumulative, shrinkage plastic strains and their distributions in the weld joint after completion of the welding process determine welding-induced distortion. Although the weldment undergoes many complex physical and metallurgical changes during welding, only the material plastic temperature range and its cooling history below this temperature range influence the [mal state of the cumulative shrinkage plastic strains. In addition, for structural welds, these plastic strains are uniform, except in the arc start and stop regions, along the weld. Therefore, the plastic strain-based "inherent shrinkage model" is effective and accurate to describe welding-induced distortion. This paper presents the theoretical background and numerical verification of this root cause.

• Journal of Welding and Joining
• /
• v.28 no.5
• /
• pp.64-68
• /
• 2010

The purpose of this study is to develop the control technology of global distortion in the deck of superstructures during manufacturing processes. The behavior of global distortion in the deck was evaluated by FEA and verified through comparing with the measured results by 3D measuring instrument. It was seen from the results that the principal factor inducing the global distortion is to be the bending moment associated with the longitudinal shrinkage force and transverse shrinkage caused by welding of stiffeners and flame heating to correct the excessive local out-of-plane distortion. Based on the results, the amount of reverse distortion in the thin deck plate was determined to control the global distortion in the deck plate. The proposed distortion control technology was verified by applying it to the actual structure.

• Journal of Welding and Joining
• /
• v.28 no.4
• /
• pp.41-48
• /
• 2010

The purpose of this study is to establish the control method of the global bending distortion caused by fabrication process of hatch-cover in a container ship. In order to do it, the transitional behavior of global bending distortion in the deck of hatch-cover during fabrication process was measured by 3-dimensional measuring instrument. From the results, the principal factor controlling the global bending distortion was identified as the bending moment associated with the longitudinal shrinkage force and transverse shrinkage caused by welding and flame heating and the change of the centroid axis of hatch-cover in each fabrication process. Therefore, in this study, with the predictive equations of the longitudinal shrinkage force and transverse shrinkage caused by welding and flame heating and the simplified thermo elastic method, the predictive method for the global bending distortion was established and verified by comparing with the measured result. Based on the results, the amount of reverse bending distortion of main stiffeners was determined to prevent the global bending distortion of hatch-cover.

• Journal of Welding and Joining
• /
• v.32 no.4
• /
• pp.69-74
• /
• 2014

Welding distortions of large steel structures had mainly been estimated with some simplified formula obtained by lots of experience and numerical analyses for small steel structures. However, the large structures would have different characteristics of distortion with welding because of their own stiffness coming from the size itself. Therefore, in order to find some measures for preventing welding distortion of large structure, it is requite in advance to precisely analysis thermal stress and distortion during welding of the structure. Numerical analysis for larger structure has been known to take large amount of calculation time and have a poor convergency problem during the thermo-elasto-plastic calculation. In this study, a hybrid method is proposed to analysis the thermal stress and distortion of a large steel plate with the finite element analysis by incorporating with temperature distribution of the plate calculated by an analytical solution. The proposed method revealed that the thermo-mechanical analysis for welding of the large structure could be performed with a good convergence and produced precise results with much reduced time consumption.

• Journal of Welding and Joining
• /
• v.28 no.3
• /
• pp.73-78
• /
• 2010

The purpose of this study is to develop the control technology of the welding distortion caused by Auto NG-GTA(Narrow Gap-GTA) welding process at the STS 304 multi-pass butt weldment. Heat input model for Auto NG-GTA welding process was established and verified by measuring temperature change and molten pool shape at the bead-on-plate weldment. With the heat input model developed, the effect of tension load on the welding distortion at the STS 304 multi-pass butt weldment was evaluated using the thermo-elasto-plastic FE analysis. In accordance with FEA results, the angular distortion and transverse shrinkage sharply decreased with an increase in tension load. This result indicated that tensioning method was an effective countermeasure against the welding distortion of the STS 304 multi-pass butt weldment.

• Journal of Welding and Joining
• /
• v.23 no.4
• /
• pp.48-52
• /
• 2005

To estimate welding deformation for large steel structures, either experiment result with small specimen or analysis result of FEM with small numerical model is used. Consequently, it is important to decide the welding length of specimen and numerical model not to have an effect on welding deformation for accurate estimation of whole welding deformation. This study experimentally clarifies the effect of welding length on angular distortion due to welding by varying welding length of specimens, but fixing width and thickness of specimens on V-groove butt welding, fillet welding and bead on plate welding. As a resell the critical welding length on fillet welding and on bead on plate welding is over 500mm and on V-groove butt welding is over 1,000mm.

• Proceedings of the KWS Conference
• /
• 2004.05a
• /
• pp.234-236
• /
• 2004

The purpose of this study is to establish the predictive equation of welding distortion at the thick AA5083 alloy weldment. In order to do it, the extensive FE analysis was peformed to identify the principal factor controlling welding distortion. Based on the results, the predictive equations of transverse shrinkage and angular distortion at the thick AA5083 alloy weldment were formulated as the function of heat intensity (Q), in-plane(Di) and bending(Db) rigidity.

• Journal of Welding and Joining
• /
• v.27 no.3
• /
• pp.44-51
• /
• 2009

In this study, welding distortion analysis is performed for various design of tube shape structures which are assembled with aluminum sheet metal. Aluminum 5052 plates of 1mm thickness are used to analyze. An efficient keyhole model, as a welding heat source, is used for the prediction of full penetration weld size and shape which is required for the thermal analysis. The thermal and mechanical material properties are considered as temperature dependent functions, due to the high temperature variations during the welding. The numerical model is calculated by using a commercial software and evaluated with the experiments. The calculation results could make a comparative study in the view of distortion for the various size and shape of structure.

• Proceedings of the KWS Conference
• /
• 2009.11a
• /
• pp.101-101
• /
• 2009

The purpose of this study is to develop the control technology of the welding distortion caused by Auto NG-GTA welding process at the STS 304 multi-pass butt weldment. For it, heat input model for Auto NG-GTA welding process was established and verified by measuring temperature change and molten pool shape at the bead-on-plate weldment. With heat input model developed, the effect of the tension load on the amount of welding distortion at the STS 304 multi-pass butt weldment was evaluated using the thermo-elasto-plastic FE analysis. In accordance with FEA results, the angular distortion and transverse shrinkage sharply decreased with an increase in tension load. This result indicates that tensioning method was verified as a countermeasure against the welding distortion of STS 304 multi-pass butt weldment.