Simulation of welding to study residual stress and distortions

The welding process has a major role in industrial production, especially in the automotive, marine, and aerospace industries. As the simulation is less expensive, the welding process simulation for a lap joint using finite element analysis can be done. In this paper, the aluminum material of the 2400 series is selected, because of its physical and thermal properties. An aluminum plate of 460*310 mm with a thickness of 3 mm lap Joint. Two stage modeling and analysis is performed. The first stage includes the design of the arc welding process for Aluminum Lap Joint. Thermal analysis of the three-dimensional moving heat source by considering the Gaussian distribution method and temperature-dependent properties comparing the actual weld pool. The adaptive Mesh technique is used in second-stage in the sequential analysis. And to determine material distortion and residual stress, the thermal analysis are imported. Proper loads and boundary conditions are applied. Experimental results are obtained through the neutron diffraction technique. Different simulation results are recorded using various types of elements. The final results are successfully validated with the experimental results with the optimum percentage error of 1.5 to 2%. (c) 2020 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Advances in Materials Processing & Manufacturing Applications.