Dimensional Analysis and Validity of Uniaxial Residual Stress Distribution for Welded Box Sections
This paper investigates the residual stresses induced by metal inert/active gas (MIG/MAG) welding in normal strength steel box sections, focusing on the validity of uniaxial residual stress assumption. Advanced manufacturing simulations are conducted using deterministic uncoupled transient thermomec...
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MDPI AG
2024-12-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/9/1/5 |
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| author | András Horváth Dénes Kollár |
| author_facet | András Horváth Dénes Kollár |
| author_sort | András Horváth |
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| description | This paper investigates the residual stresses induced by metal inert/active gas (MIG/MAG) welding in normal strength steel box sections, focusing on the validity of uniaxial residual stress assumption. Advanced manufacturing simulations are conducted using deterministic uncoupled transient thermomechanical analysis with a double-ellipsoidal heat source model, employing 8-node solid elements and material models calibrated for extreme temperatures per EN 1993-1-2. A comprehensive parametric analysis investigates the effects of primary welding variables, such as heat source power and welding speed, alongside geometric parameters of the heat source model using random Latin hypercube sampling technique in the analyzed parameter set. The relationship between the size and shape of the characteristic isotherms, i.e., the aspect ratio and the Rosenthal number, underscores that the analyzed welding heat sources are in the fast regime with the validity of uniaxial residual stresses based on the analytical assumption (minimal values are AR = 9.94 and Ro = 30.47). The validity and limitations of uniaxial residual stress assumptions for 59 welded and 51 heated box sections are critically evaluated by using the finite element model-based stress triaxiality parameter. Results confirm that longitudinal residual stresses dominate typical MIG/MAG welding applications, supporting the application of uniaxial residual stress models in advanced structural design by neglecting in-plane and through-thickness residual stresses. Conversely, three-dimensional residual stress state dominates under conditions such as preheating or thermal straightening. |
| format | Article |
| id | doaj-art-335aeaea56e4421690cf76e7a80acb42 |
| institution | Kabale University |
| issn | 2504-4494 |
| language | English |
| publishDate | 2024-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-335aeaea56e4421690cf76e7a80acb422025-01-24T13:36:25ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942024-12-0191510.3390/jmmp9010005Dimensional Analysis and Validity of Uniaxial Residual Stress Distribution for Welded Box SectionsAndrás Horváth0Dénes Kollár1Department of Structural Engineering, Faculty of Civil Engineering, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, HungaryDepartment of Structural Engineering, Faculty of Civil Engineering, Budapest University of Technology and Economics, Műegyetem rkp. 3., H-1111 Budapest, HungaryThis paper investigates the residual stresses induced by metal inert/active gas (MIG/MAG) welding in normal strength steel box sections, focusing on the validity of uniaxial residual stress assumption. Advanced manufacturing simulations are conducted using deterministic uncoupled transient thermomechanical analysis with a double-ellipsoidal heat source model, employing 8-node solid elements and material models calibrated for extreme temperatures per EN 1993-1-2. A comprehensive parametric analysis investigates the effects of primary welding variables, such as heat source power and welding speed, alongside geometric parameters of the heat source model using random Latin hypercube sampling technique in the analyzed parameter set. The relationship between the size and shape of the characteristic isotherms, i.e., the aspect ratio and the Rosenthal number, underscores that the analyzed welding heat sources are in the fast regime with the validity of uniaxial residual stresses based on the analytical assumption (minimal values are AR = 9.94 and Ro = 30.47). The validity and limitations of uniaxial residual stress assumptions for 59 welded and 51 heated box sections are critically evaluated by using the finite element model-based stress triaxiality parameter. Results confirm that longitudinal residual stresses dominate typical MIG/MAG welding applications, supporting the application of uniaxial residual stress models in advanced structural design by neglecting in-plane and through-thickness residual stresses. Conversely, three-dimensional residual stress state dominates under conditions such as preheating or thermal straightening.https://www.mdpi.com/2504-4494/9/1/5box sectionwelding simulationresidual stressesdimensional analysisisothermaspect ratio |
| spellingShingle | András Horváth Dénes Kollár Dimensional Analysis and Validity of Uniaxial Residual Stress Distribution for Welded Box Sections Journal of Manufacturing and Materials Processing box section welding simulation residual stresses dimensional analysis isotherm aspect ratio |
| title | Dimensional Analysis and Validity of Uniaxial Residual Stress Distribution for Welded Box Sections |
| title_full | Dimensional Analysis and Validity of Uniaxial Residual Stress Distribution for Welded Box Sections |
| title_fullStr | Dimensional Analysis and Validity of Uniaxial Residual Stress Distribution for Welded Box Sections |
| title_full_unstemmed | Dimensional Analysis and Validity of Uniaxial Residual Stress Distribution for Welded Box Sections |
| title_short | Dimensional Analysis and Validity of Uniaxial Residual Stress Distribution for Welded Box Sections |
| title_sort | dimensional analysis and validity of uniaxial residual stress distribution for welded box sections |
| topic | box section welding simulation residual stresses dimensional analysis isotherm aspect ratio |
| url | https://www.mdpi.com/2504-4494/9/1/5 |
| work_keys_str_mv | AT andrashorvath dimensionalanalysisandvalidityofuniaxialresidualstressdistributionforweldedboxsections AT deneskollar dimensionalanalysisandvalidityofuniaxialresidualstressdistributionforweldedboxsections |