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A dual-mesh method for efficient thermal stress analysis of large-scale welded structures

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Abstract

Transient thermo-mechanical analysis of welding problem requires tremendous computation cost. To accelerate the thermal analysis of large-scale welded structures, an efficient computation scheme based on heat transfer localization and dual meshes was proposed. The computation accuracy is guaranteed by a local fine mesh model with size determined by a theoretical solution and a global coarse mesh model with equivalent heat input. The validity and accuracy of the dual-mesh method were verified using an experimental bead-on-plate model. By extending the weld length, the computation time of the proposed method was proved to be almost linearly dependent on the model scale. The thermal analysis of fillet welding of a large panel structure with 6-m-long weld was accelerated by 10 times over conventional finite element analysis and 2.2 times over adaptive mesh method. Meanwhile, the physical memory consumption was also greatly reduced by the dual-mesh method. Such efficient computation method enables fast evaluation of welding stress and distortion which are vital for manufacturing process and structure performance.

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Acknowledgements

The first author Hui Huang is very grateful to the Japanese Government (Monbukagakusho: MEXT) Scholarship for supporting his doctoral study in Osaka University, Japan. This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

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Authors and Affiliations

  1. Joining and Welding Research Institute, Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka, 567-0047, Japan

    Hui Huang, Ninshu Ma & Hidekazu Murakawa

  2. Oak Ridge National Laboratory, 1 Bethel Valley Road, Oak Ridge, TN, 37831, USA

    Hui Huang & Zhili Feng

Authors
  1. Hui Huang
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  2. Ninshu Ma
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  3. Hidekazu Murakawa
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  4. Zhili Feng
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Correspondence to Hui Huang.

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Huang, H., Ma, N., Murakawa, H. et al. A dual-mesh method for efficient thermal stress analysis of large-scale welded structures. Int J Adv Manuf Technol 103, 769–780 (2019). https://doi.org/10.1007/s00170-019-03606-4

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  • DOI: https://doi.org/10.1007/s00170-019-03606-4

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