Analysis Of Shovel Welding Residual Stress Based On Finite Element Method

Welding residual stress and deformation occurred inevitably in the welding process because of the rapid non-equilibrium heating and cooling, and it can't be ignored. Residual deformation is a key factor affects the structural design integrity, manufacturing process and the use of structure reliability. The post-weld correction, both diseconomy and injure severely its operational reliability. It is very important to weld engineering if we can scientific, quantitative prediction of welding deformation and give some control on this basis.The main work and research results of this paper summarized as follows:(1) As there are too many weld seams on the shovel, and cost a long time to weld, so the weld sequence impact the welding residual stress highly. This article take shovel welding as an example, developed two welding sequence first, and then analyzed and developed the third welding sequences according to the affects of neutral axis.(2) Finite element analysis software ANSYS used to establish the 3-D model for shovel, simulate the tress field which generated by the welding, establish finite element welding model for shovel, then simulate the welding process by birth and death element technology. Three different welding sequences were carried on the finite element to simulate, obtained the welding residual stress distribution and the welding deformation.(3) Weld the shovel according to the three different sequences, and then this article has also utilized the straight edge and the high accuracy measuring instrument CMM (Coordinate Measuring Machining) measure the shovel after the actual welding, compared and analyzed their welding deformation.(4) Finally we compared and analyzed the simulation results and the measurement results, and it showed that simulation results coincide with experimental results. It proved the important of neutral axis in the welding sequence optimization, and had certain application value.Verified through research and examples, this paper establishes a viable shovel thermal stress dynamic simulation and analysis, provided a theoretical and guidance for three-dimensional structure for complex welding temperature field, residual stress analysis.