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Numerical modelling and experimental analysis on angular strain induced by bead-on-plate SS316L GMAW using inherent strain and thermomechanical methods

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Abstract

This study presents a basic investigation on angular strain behaviour of substrate using experiment and three different numerical computations based on elastic and elastic–plastic FEM methods. In simulation, a 3D simplified rectangular weld bead geometry was modelled and computed using general purposed numerical software MSC Marc/Mentat. While elastic FEM with well-known inherent strain method-user defined (ISM-UD) and new ISM weld-kinematics (ISM-WK) were applied in which the inherent strain values were empirically estimated with regard to process parameters, physical properties, and effective area on heat affected zone, the most popular elastic–plastic or thermo-mechanical method (TMM) considers temperature-dependent isotropic hardening rule and heat source model. For verification purpose, experimental analysis was conducted as bead-on-plate process with austenitic stainless steel material SS316L using GMAW robotic welding. It can be concluded that TMM can predict the total experimental angular strain with mean percentage error up to ca. 7% compared to ISM with 19% for weld kinematics and 29% for user defined. In terms of computational time, ISM gave higher potential to be implemented with only 10% of TMM.

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Acknowledgements

The authors would like to express their gratitude to the staff members of Smart Manufacturing Research Institute (SMRI) and Research Interest Group: Advanced Manufacturing Technology (RIG:AMT) at School of Mechanical Engineering, Universiti Teknologi MARA (UiTM) Shah Alam for encouraging this research.

Funding

This research is financially supported by ASEA-UNINET grant with the project number ASEA 2019/Montan/1, ERASMUS + (Montan University in Leoben), Geran Penyelidikan Khas (GPK) with Project Code: 600-RMC/GPK 5/3 (123/2020), Geran Konsortium Kecemerlangan Penyelidikan (Large Volume Additive Manufacturing/LVAM) from Ministry of Higher Education (MOHE) in Malaysia, Geran Penyelidikan Khas (GPK) with Project Code: 600-RMC/GPK 5/3 (123/2020), and Technogerma Engineering and Consulting Sdn. Bhd. with Project Code: TEC/SMRI/2020–2021/01.

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Authors and Affiliations

  1. Smart Manufacturing Research Institute (SMRI) and College of Engineering, Universiti Teknologi MARA (UiTM), Shah Alam, Malaysia

    Siti Nursyahirah Ahmad, Yupiter H. P. Manurung, Keval P. Prajadhiana, Yusuf O. Busari & Muhd Faiz Mat

  2. Jabatan Kejuruteraan Mekanikal, Politeknik Sultan Salahuddin Abdul Aziz Shah, Shah Alam, Malaysia

    Norasiah Muhammad

  3. Institute of Structural Durability and Railway Technology, Graz University of Technology, Graz, Austria

    Martin Leitner

  4. NDT Lab and Metrology Lab, Nusantara Technologies Sdn. Bhd., Shah Alam, Malaysia

    Salina Saidin

Authors
  1. Siti Nursyahirah Ahmad
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  2. Yupiter H. P. Manurung
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  3. Keval P. Prajadhiana
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  4. Yusuf O. Busari
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  5. Muhd Faiz Mat
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  6. Norasiah Muhammad
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  7. Martin Leitner
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  8. Salina Saidin
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Contributions

Siti Nursyahirah Ahmad: Writing manuscript, simulation of TMM and ISM. Yupiter HP Manurung: Experiment using Robotic Welding and Simulation of TMM. Keval P Prajadhiana: Experiment using Robotic Welding. Yusuf O. Busari: Writing manuscript. Muhd Faiz Mat: Writing manuscript and measurement using CMM. NorAsiah Muhammad: Writing manuscript and measurement using CMM. Martin Leitner: Writing manuscript and analysis. Salina Saidin: Writing manuscript and analysis.

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Correspondence to Yupiter H. P. Manurung.

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Ahmad, S.N., Manurung, Y.H.P., Prajadhiana, K.P. et al. Numerical modelling and experimental analysis on angular strain induced by bead-on-plate SS316L GMAW using inherent strain and thermomechanical methods. Int J Adv Manuf Technol 120, 627–644 (2022). https://doi.org/10.1007/s00170-022-08684-5

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