Efficient finite element approach for modelling of actual welded structures

As the basis of the finite element analysis of a welding process, two mathematical models for the welding heat source are presented, based on a Gaussian distribution of power density. One is the prolonged Gaussian heat source model, and the other is the prolonged point heat source model. Finite element simulations of a bead on plate welding process were carried out using the circular disc heat source model, prolonged Gaussian heat source model, and prolonged point heat source model Comparisons of the temperature, distortion, and stress obtained show that the combination of the new,models and a reasonable mesh can greatly increase the computational efficiency while maintaining a relatively high accuracy. In the present paper, both finite element predictions of distortion for huge complex welded beams and workshop experiments were carried out. The numerical results were in reasonable agreement with the experimentally determined distortion values. (C) 2003 IoM Conununications Ltd. Published by Money for the Institute of Materials, Minerals and Mining.