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 |  موضوع: كتاب Finite Element Analysis of Weld Thermal Cycles Using ANSYS الأحد 18 أغسطس 2024, 1:40 am | |
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أخواني في الله
أحضرت لكم كتاب
Finite Element Analysis of Weld Thermal Cycles Using ANSYS
G. Ravichandran
General Manager (Retd)
Welding Research Institute
BHEL, Tiruchirappalli
Professor Adjunt
NMAM Institute of Technology
Nitte, Karnataka
و المحتوى كما يلي :
Contents
Preface vii
Author .ix
Chapter 1 Introduction 1
Chapter 2 Arc Welding Processes .5
2.1 Electric Arc .5
2.2 Classification of Welding Processes 7
2.3 Welding Power Source 8
2.4 Welding Techniques 10
2.5 Shielded Metal Arc Welding Process . 11
2.6 Submerged Arc Welding Process 12
2.7 Gas Tungsten Arc Welding Process 13
2.8 Gas Metal Arc Welding Process . 15
Chapter 3 Thermal Cycles and Heat Flow in Welding . 17
3.1 Heating and Cooling Cycles 17
3.2 Heat Flow in Base Metal . 18
3.3 Graphical Plotting of Results 19
3.4 Factors Influencing Thermal Cycles .22
3.5 Simplification of Three-Dimensional Model 23
Chapter 4 Finite Element Analysis .25
4.1 Shape Function 25
4.1.1 Shape Function for a One-Dimensional Simplex
Element 25
4.1.2 Shape Function for a Four Noded Quadrilateral
Element 27
4.2 Formulation of Equation .29
4.3 Finite Element Analysis Using ANSYS 32
Chapter 5 Arc Heat Model 35
5.1 Cross Sectional Analysis .39
5.2 In-Plane Analysis 49
References 107vi Contents
Chapter 6 Sample Problems 109
6.1 Cross Sectional Analysis of a Submerged Arc
Welded Plate . 109
6.2 In-Plane Analysis of a Gas Metal Arc Welded Plate 126
6.3 In-Plane Analysis of a Gas Metal Arc Welded Dissimilar
Weldment 144
6.4 In-Plane Analysis of a Gas Metal Arc Welded Plate 167
6.5 Three-Dimensional Analysis of a Gas Tungsten Arc
Welded Tube 186
Chapter 7 Conclusion 207
Appendix: Exercise Problems .209
Bibliography . 221
Index 223
Index
A
abstraction of heat, 18
aftereffects, 2–3, 17
aluminium alloy, 2
animation, 32
ANSYS, 3, 32–33, 109–110, 111–118, 132,
134–139, 152–153, 156–161, 173,
177–181, 192, 197–200
APDL, 32–33, 109, 111, 132, 155, 176, 193
arc, 2, 5–8, 10–15, 17, 19–23, 35–41, 42–43, 45,
48–55, 69–71, 86, 90, 93, 109–111,
126–130, 132, 133, 144–145, 146, 147,
152–153, 154, 155, 167–168, 173, 174,
176, 186–187, 189, 192, 193, 209, 210,
212, 213, 214, 215, 217, 218, 219
diameter, 10–11, 35, 45, 50–51, 54–55, 85, 90,
126, 129, 144, 152, 167, 186, 209, 213,
215, 217–218
heat, 6–8, 11, 17, 22, 32–33, 35–42, 43, 45, 49,
50–52, 55, 69–71, 84, 85–86, 90, 91–92,
93–101, 102–107, 109–110, 127, 128,
129–130, 132, 145, 152, 154, 155, 168,
173, 187, 188–191, 209, 210–212, 213,
214, 215, 216, 217–218, 219–220
length, 6–9, 11, 15, 35, 36
radius, 39, 42, 45
welding, 1–2, 5–7, 11–17, 45, 55, 71, 85, 90,
126, 144, 167, 186, 207, 209, 215, 217
argon, 13
automatic mesh generation, 32
automatic voltage correction, 8, 15
automatic welding, 7–9, 12, 15, 35
automation, 1
B
backhand technique, 10, 35, 36
base material, 1
base metal, 2, 5–8, 10–15, 17–19, 21, 35–36
basic coated electrode, 12
beam energy, 5
beam welding process, 35
blanketing action, 13
boundary condition, 25, 30, 110
C
carbon steel, 2, 144, 155
cellulose coated electrode, 12
chemical energy, 5
chemical reaction, 11
circular, 35–37, 69
coalescence, 1, 17
computation, 3, 45, 69
conduction, 17–19
constant current characteristics, 9
constant voltage characteristics, 8, 9
consumable electrode, 6–8
convection, 6, 12–13, 17–18, 22, 30, 32, 110
coefficient, 18, 30, 110
convergence, 31, 44, 54
cooling phase, 2, 12, 50, 132, 152, 173,
176, 192
coordinate, 25–28, 32, 37, 38–39, 93, 168
cross section, 19, 23, 40–41, 109, 110
cross sectional analysis, 39, 41, 109,
111, 115
cross sectional model, 19, 23
current, 5–9, 11–17, 22, 31, 37, 45, 51, 55, 69, 71,
85, 90, 109, 126, 144, 152, 167, 186,
209, 215, 217
cushioning, 10
D
degradation, 3
density, 6, 11, 22, 29, 32, 35, 109, 127, 145
differential thermal expansion, 2
digging, 6, 10
direct generation, 32, 109, 129, 152, 173, 189
discretization, 43, 109, 111, 115, 129, 131, 134,
152, 153, 156, 173, 173, 177, 189,
192, 197
dissimilar, 5, 144
dissipation, 17
distortion, 2
distributed arc heat, 22
double integration, 52, 54
downhand, 10, 13
ductility, 2224 Index
E
egen, 32, 109
electrical energy, 5
electric arc, 2, 5, 7, 15, 17
electric discharge, 5
electrode, 5–15, 35
feed rate, 7–8
melting rate, 8
stub, 11
element, 3, 25–28, 30, 32–33, 35, 43, 44–45,
46–47, 48, 50–55, 69, 70–71,
84–86, 90, 91, 92, 93–100,
101, 102–107, 109, 126, 128–129,
130–131, 144–145, 146, 147, 148–151,
152, 167–168, 169, 170–171, 173,
186–187, 188, 189, 190–191, 192,
209, 210–212, 213, 214, 215,
216–217, 219
size, 32, 51, 109, 129, 144, 148, 167, 173, 186,
189, 209, 213, 215, 217–218
type, 32–33
elliptical, 35
emissivity, 18
energy, 1–2, 5–7, 17
density, 35
excel, 45, 56
F
fabrication, 1
field variable, 25–27
filler metal, 6, 8, 13–14
finite element analysis, 25, 32, 50, 52
finite element method, 3, 25, 207
flux, 7, 11–13, 15, 17
cored arc welding, 15
shielded welding processes, 7
forced cooling, 18
force matrix, 30
forehand technique, 10, 35, 36
fusion, 2–3, 5–6, 8
welding, 5
G
gaseous matter, 5
gas metal arc welding, 15, 55, 71, 90, 126, 144,
167, 209, 215
gas shielded welding processes, 7
gas tungsten arc welding, 13–14, 85, 186, 209,
217–218
Gaussian distribution, 36, 37
grain coarsening, 2
grain refining, 2
H
hardening, 2
heat affected zone, 2, 5
heat capacitance matrix, 30
heat conductance matrix, 30
heat distribution, 35, 48, 128–129, 168, 170–172,
187, 188–191, 209, 215, 217–218
heat flux, 17, 29, 36–39, 42, 44–45, 52–54, 129, 152
heat input, 2–3, 10, 13–14, 17, 23, 32–33, 35,
39–42, 44, 48, 49, 50–52, 55–56, 69,
84, 87–89, 90, 96–97, 101, 109–110,
126–127, 129, 130–131, 132, 133–134,
145, 147–148, 149–151, 152, 154, 155,
168, 169, 171–172, 173, 175–176, 186,
187, 188, 194–196, 210–220
heat loss, 6, 13, 17–18, 22, 30, 32–33
helium, 13
horizontal, 1
I
impure elements, 2
inclusion, 2, 7
inert gas, 7, 13
in-plane analysis, 39, 49, 50, 126, 144, 167, 186
integrity, 2, 7
interpolation function, 25, 27
isotherms, 20–21
iteration, 31
iterative, 22, 31
J
joining, 1, 5
joint line, 1–2, 7
joint strength, 1
K
kesize, 32, 109
keypoints, 32, 109
L
lamellar tearing, 2
latent heat, 22
lateral direction, 10, 19, 21
length, 7, 11, 27, 33, 41, 44–45, 49, 54–55, 71,
126, 129, 152, 167, 173, 187
linear, 25, 27
localized heat, 2, 17
localized plastic deformation, 2
longitudinal, 21, 23, 33
low alloy steel, 2Index 225
M
magnetic forces, 6, 22
manual welding, 7–9
material properties, 17, 22, 31–32, 126, 127, 144,
167, 187
mechanical properties, 11–15
melting point, 2, 5, 17, 20, 22, 145
metal deposition rate, 7
metallurgical bond, 1–2, 5
metallurgical damage, 1
metallurgical issues, 1
metallurgical phase change, 2
mid-section, 2, 49
molten pool, 5–6, 10, 12, 20, 22–23, 35
motorized carriage, 12
motorized drive, 15
moving heat source, 19
multipass welding, 2
N
natural cooling, 18
Newton Raphson’s method, 31
ngen, 32, 109
nodal heat, 44, 48, 51, 55, 71, 85, 90, 130–131,
132, 133–134, 148, 168, 171–172, 173,
175–176, 188, 194–196
nodal temperature, 25–27, 29–31, 110
node, 25–29, 32–33, 39–42, 43, 44, 48, 49, 50–52,
55–56, 57–68, 69, 70–71, 72–83,
84, 85, 86, 90, 91–92, 101, 102–107,
109–110, 127, 129, 130–131, 132,
133–134, 145, 148, 149–151, 152–153,
154, 155, 167–168, 169, 171–172, 173,
175–176, 186, 187, 188–189, 190–191,
192, 194–196, 210–220
non consumable electrode, 8, 13
non linear, 22, 31
non uniform heating, 2
numerical integration, 44, 54
numerical technique, 3, 25
O
one dimensional, 25, 26
operator skill level, 1
overhead, 10
P
penetration, 10, 12, 14
periphery, 36–37
phenomena, 3, 17, 22, 207
phenomenon, 2, 5–6, 22
plastic deformation, 2
polarity, 14
polynomial, 25, 27
postprocessor, 32–33
post weld heat treatment, 1
power of the arc, 7
power source, 5, 8–9, 14–15
precipitation, 2
preheating, 1
preprocessor, 32
pressure welding, 5
process efficiency, 6–7, 13–14, 16–17, 37, 45, 51,
55, 69, 71, 85, 90, 109, 126, 144, 152,
167, 186, 209, 215, 217–218
productivity, 1, 12
Q
quadrilateral element, 25, 27, 33, 55
R
radial distance, 36–37
radiation, 6, 12–13, 17–18
rectangular element, 50, 54–55, 71, 84, 101
reliability, 1, 22
residual stress, 2, 19
restraint, 2
reverse polarity, 14
riveting, 1
running characteristics, 12
rutile coated electrode, 12
S
segregation, 2
shape factor, 33
shape function, 25–30, 44–45, 52, 54, 92
shielded metal arc welding, 11–12
shrinkage forces, 2
simplex element, 25, 26, 44
Simpson’s rule, 44, 54–55
slag, 11–12
metal reaction, 12–13
softening, 2
software, 3, 32
solidification, 2, 5
solid modeling, 32
solid phase welding, 5
solution, 3, 32–33, 207
spatial distribution of heat, 19
spatter, 6, 12–13
specific heat, 17, 22, 29, 31–32, 109, 126, 127,
144, 167, 187
spreadsheet, 45, 56226 Index
stainless steel, 2, 144, 155
stationary heat source, 19
straight polarity, 14
stray heat flux, 37, 129, 152
stringer bead, 11
submerged arc welding, 12, 13, 16, 45, 109, 209
subsurface, 35
superheat, 17
surface area, 18, 186
symmetrical, 45, 145
symmetry, 41, 43, 52, 109, 126, 144, 167, 187
T
temperature, 2–3, 5, 7, 17–23, 25–27, 29–33, 35,
51, 110–111, 127, 132, 144, 155, 193
dependency, 22
dependent, 31, 126, 127, 144, 167, 187
distribution, 21, 22, 33, 112–114, 116–118,
135–139, 156–161, 177–181, 198–200
gradient, 17, 21, 23, 32
profile, 17
thermal conductivity, 17–18, 22, 31–32, 109, 126,
127, 144, 167, 187
thermal cycles, 3, 17, 20, 22–23, 53
thermal gradient, 18, 23, 193
thickness, 2, 6, 17–18, 21, 23, 35, 45, 126, 144,
167, 186, 189, 193
three dimensional, 18–19, 21, 23, 25, 32, 39,
40, 186
time increment, 31, 45, 51, 54, 69–70, 109–111,
126–127, 132, 167, 176, 187, 192
time interval, 20, 21, 22, 25, 30, 32–33, 38,
48–49, 51, 69, 71, 84, 86, 90, 93,
109–111, 132, 168, 176, 188, 192,
209, 215
time lag, 23, 39, 147
time marching scheme, 31
time step, 25, 31–32, 33, 41–42, 44–45, 48, 49,
51, 53, 54, 55, 69, 70–71, 84, 86, 90,
96–97, 101, 109–110, 126–127, 132,
133–134, 144–145, 147, 153, 154,
155, 167–168, 173, 186, 187, 192, 209,
210–212, 213, 214, 215, 216, 217–218,
219–220
toughness, 2, 13
transient, 25, 29–33, 207
transverse, 19, 21, 22, 23, 33
two dimensional, 18–19, 21, 23, 25, 32, 41, 49–50,
126, 167
tungsten electrode, 8, 13, 15
V
vaporization, 6, 17, 22, 35
vertical, 10
voltage, 6–9, 12–17, 35, 37, 45, 51, 55, 69, 71, 85,
90, 109, 126, 144, 152, 167, 186, 209,
215, 217–218
W
weaving, 10–11
weightage factor, 45, 54, 56
weld discontinuities, 1
welding, 1–3, 5–19, 23, 32, 35, 45, 55, 71, 85,
90, 102–107, 109, 126, 128, 144, 152,
167–168, 186–187, 207, 209, 215,
217–218
phase, 49–50, 155
procedure, 1
process, 1–3, 5–17, 35, 37, 41, 45, 55, 85, 90,
109, 126, 144, 167, 186, 207, 209, 215,
217–218
speed, 7, 11–14, 16, 39, 45, 51, 54, 70–71, 85,
90, 109, 126, 144, 167, 186, 209, 213,
215, 217–218
torch, 13
weld line, 7, 12, 14–15, 20, 49–51, 53, 132, 145,
153, 174
width, 6, 11, 27, 33, 45, 54–55, 86, 90, 92,
126, 152
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