Project Overview
In this example, the arc welding process is simulated using the DFLUX subroutine in the Abaqus software.
A volumetric heat flux is used to simulate the welding process. The Goldak's double-ellipsoid heat source model is used to define the volumetric heat flux around the welding pool.
The DFLUX subroutine is implemented to define the Goldak's double-ellipsoid heat source and apply the nonuniform heat flux during the welding process.
Simulation of the arc welding process using the DFLUX subroutine.
Goldak's Double-Ellipsoid Heat Source
The Goldak's double-ellipsoid heat source model is adopted to calculate the volumetric heat flux distribution around the welding pool.
The Goldak heat source equations are defined as a function of position and time, together with several heat source parameters.
The parameters a, b, Cf, and Cr define the size and shape of the two ellipsoids representing the heat source. These heat source parameters are obtained from experimental analysis.
Goldak's double-ellipsoid heat source model used to calculate the volumetric heat flux distribution.
Welding Parameters
The welding parameters used in this simulation are defined based on the welding conditions of the model.
- Welding voltage: 22 V
- Welding current: 110 A
- Welding efficiency: 0.8
- Welding speed: 10 mm/s
These parameters are used to determine the heat input applied to the welding model.
Welding and Cooling Process
The analysis is performed in two steps.
In the first step, the welding process is simulated for a duration of 20 seconds. During this step, the moving volumetric heat flux is applied using the DFLUX subroutine.
In the second step, the welding heat source is removed and the cooling process is simulated for a duration of 120 seconds.
Welding stage followed by the cooling process.
Thermal-Mechanical Analysis
Two Coupled Temperature-Displacement steps are defined to simulate the thermal and mechanical behavior of the welded plate.
This approach allows the temperature field and the resulting mechanical response of the plate to be considered simultaneously during the welding and cooling processes.
Material Properties
The material of the plate is SUS304 stainless steel.
The material properties are defined as temperature-dependent properties. The following properties depend on temperature:
- Density
- Thermal conductivity
- Specific heat
- Thermal expansion
- Elastic properties
- Plastic properties
Residual Stress
One of the important results obtained from the simulation is the residual stress generated in the welded plate.
The S33 stress component is evaluated to investigate the residual stress distribution after the welding process.
The results include both the longitudinal residual stresses, which are the residual stresses along the welding path, and the transversal residual stresses, which are the residual stresses perpendicular to the welding path.
Longitudinal residual stress along the welding path.
Transversal residual stress perpendicular to the welding path.
What You Will Learn
- How to simulate arc welding in Abaqus.
- How to use the DFLUX subroutine for arc welding.
- How to define a volumetric heat flux.
- How to implement Goldak's double-ellipsoid heat source.
- How to define a nonuniform heat flux using DFLUX.
- How to define the welding heat input.
- How to define welding voltage and current.
- How to define welding efficiency.
- How to define a welding speed of 10 mm/s.
- How to define Goldak heat source parameters.
- How to define the parameters a, b, Cf, and Cr.
- How to perform a 20-second welding step.
- How to perform a 120-second cooling step.
- How to perform a Coupled Temperature-Displacement analysis.
- How to define temperature-dependent material properties.
- How to evaluate residual stress after welding.
- How to obtain longitudinal residual stresses.
- How to obtain transversal residual stresses.
- How to evaluate the S33 stress component.
- How to implement a Fortran DFLUX subroutine in Abaqus.
Temperature diagram.
Key Features
- Arc welding simulation in Abaqus.
- DFLUX Fortran subroutine.
- Volumetric heat flux.
- Goldak's double-ellipsoid heat source model.
- Nonuniform heat flux distribution.
- Welding voltage: 22 V.
- Welding current: 110 A.
- Welding efficiency: 0.8.
- Welding speed: 10 mm/s.
- 20-second welding stage.
- 120-second cooling stage.
- Two Coupled Temperature-Displacement steps.
- Temperature-dependent material properties.
- SUS304 stainless steel.
- Goldak parameters a, b, Cf, and Cr.
- Longitudinal residual stress.
- Transversal residual stress.
- S33 stress evaluation.
- Research article included.
Project Information
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