4/14/2018 Estimate Weld Distortion Using SOLIDWORKS Simulation

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How to Estimate Weld Distortion Using SOLIDWORKS

Simulation
By Karol Rapacz (http://blogs.solidworks.com/tech/author/krapacz) November 14, 2015

SOLIDWORKS Simulation (Professional and Premium package) allow us to find stress distribution
on the weld connection as well as the appropriate weld size. However, calculated stress appears
as a result of force applied to the welded elements, not as a result of thermal distortion which is
often more important from engineering point of view.

In the following article you will find out how to estimate weld distortion using SOLIDWORKS
Simulation.

Our case study consists of two metal sheets which will be welded together – we want to find out
what is the distortion and stress distribution resulting from the thermal load (pic. 1). The length
of weld connection is 100 [mm] and the welding speed is 0.3 [m/min] that gives us 20 seconds
of welding time.

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(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/128.png)

pic. 1 Case study – Two metal sheets which will be welded together

The first thing we have to do is to model 3D geometry of weld connection (pic. 2). Then we
should split our weld model into smaller pieces adequately to the welding time – 20 seconds =
20 pieces
(pic. 3).
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(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/218.png)
pic.2 3D model of weld connection

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(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/317.png)
pic.3 Weld connection after splitting

The next step is to define new thermal study. In the study properties we change Solution type to
transient and the total study time to 21 seconds (pic. 4).

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Now materials should be defined both for metal sheets and weld.

Two kind of thermal loads will be added to the study. Firstly, temperature load – we pick initial
temperature and then select all exposed faces option and set the temperature to 20 [°C] (pic.
5).

The second thermal load will be Heat power with the value of 2000 [W]. In that case we will use
time curve and set it as follows – for x=0 (second 0) y=0 (no thermal load) for x=1 (second 1)
y=1 (thermal load 2000 [W]) for x=2 (second 2) y=0 (no thermal load). This operation should
be repeated for all the pieces of weld with proper timing (pic. 6, pic. 7).

(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/417.png)

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pic.4 Properties of Thermal study

(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/513.png)
pic.5 Initial temperature definition

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(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/613.png)
pic.6 Definition of thermal loads on the first piece of weld connection

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(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/710.png)
pic.7 Definition of thermal loads on the second piece of weld connection

Now we can run the study which results are presented below as animation.

Obciążenie termiczne / Transient thermal load

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4/14/2018 Estimate Weld Distortion Using SOLIDWORKS Simulation

In the last step we will create nonlinear study (available only for Premium Simulation). In the
study, properties in Solution tab End of stepping time should be set to 21 seconds with fixed
Time increment to 1 (pic. 8). In the Flow/Thermal Effects tab Temperatures from thermal study
option should be picked up (pic. 9). We add global contact – bonded and define fixed geometry
on the bottom surface of bottom plate and run the study.

As a result we can analyze Stress distribution (pic. 10a) and Displacement plot (pic. 10b) for
chosen second of the analysis or for all iterations at once (pic. 11a – stress, pic. 11b
displacement). The results are also represented as animation below (stress and displacement
respectively with the deformation scale of 10).

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(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/87.png)

pic.8 Properties of Nonlinear study (Solution)

(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/87.png)

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(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/96.png)

pic.9 Properties of Nonlinear study (Flow/Thermal Effects)

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(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/106.png)
pic.10a Stress plot in 10th second

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(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/10a.png)
pic.10b Displacement plot (distortion) in 13th second

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(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/1111.png)
pic.11a Stress plot for whole study

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(http://blogs.solidworks.com/tech/wp-content/uploads/sites/4/11a.png)
pic.11b Displacement plot (distortion) for whole study

Naprężenia spawalnicze / Stress from thermal loads

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Skurcz spawalniczy / Weld distortion

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4/14/2018 Estimate Weld Distortion Using SOLIDWORKS Simulation

If you want to check up study definition on yourself you can download it from DROPBOX from
link below

DROPBOX
(https://www.dropbox.com/s/xiq6r7p0xiuiu7q/Naprezenia%20i%20skurcz%20spawalniczy.SLDPRT?
dl=0)

Bio Latest Posts

Karol Rapacz
Technical Support Engineer at SOLIDEXPERT (http://www.solidexpert.com)

Civil Engineering and Mechanical and Construction Engineering student. Currently

SOLIDEXPERT (Polish VAR) employee as a Technical Support Engineer for
SOLIDWORKS SImulation, SOLIDWORKS Flow Simulation and SOLIDWORKS
Motion modules. Experience in designing cooling systems (CERN Switzerland -
CMS experiment) and industry solutions (Air Liquide)

Categories: SOLIDWORKS Simulation (http://blogs.solidworks.com/tech/category/solidworks-

simulation), Tips & Tricks (http://blogs.solidworks.com/tech/category/tips-tricks)
Tags: FEA Analysis (/tech/tag/fea-analysis), SOLIDWORKS Simulation (/tech/tag/solidworks-
simulation), Welded Structure FEA (/tech/tag/welded-structure-fea), Weldments
(/tech/tag/weldments)

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4/14/2018 Estimate Weld Distortion Using SOLIDWORKS Simulation

Karol Rapacz • 2 years ago

Sorry I didn't notice that. You can find the file in the following link:
https://www.dropbox.com/s/d...
1△ ▽ • Reply • Share ›

datopaz > Karol Rapacz • 2 years ago

thanks for share..
△ ▽ • Reply • Share ›

michael • 2 years ago

Hi Karol

the link doesn't work, could you please reupload the file ?
△ ▽ • Reply • Share ›

Sergio Leon • 2 years ago

Hello Karol, could you please put the link again. I ll be apreciate it a lot.
△ ▽ • Reply • Share ›

FlowJoe • 2 years ago

Karol, how about also accounting for temperature-dependent material properties that SW SIM
can also handle?
△ ▽ • Reply • Share ›

datopaz • 2 years ago

the link doesn't works,mind if you re-upload the file?
△ ▽ • Reply • Share ›

Mondeo14 • 2 years ago

The file link does not work, could you please repeat that?
△ ▽ • Reply • Share ›
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