© January 2017 | IJIRT | Volume 3 Issue 8 | ISSN: 2349-6002
Experimental Investigation and Analysis of Welding
Distortion for Prediction and Better Reduction
Techniques
Mr. Ruchit V. Patel1, Prof. Hardik V. Naik2, Dr. Piyush S. Jain3
1
M.E. Student, Sitarambhai Naranji Patel Institute of Technology and Research Centre.
2
Assi. Professor, Sitarambhai Naranji Patel Institute of Technology and Research Centre.
3
Head oF Mechanical Dept., Sitarambhai Naranji Patel Institute of Technology and Research Centre.
Abstract—Arc welding is an important joining process
widely used in many industrial applications including
production of automobile, ships structures and industrial
parts. In welding process, the moving electrode causes
highly non-uniform temperature distribution that leads
to residual stresses and distortions in thin plates. To
control the distortions and increase the quality of welded
plates, a clamp can be used as a practical and low cost
method with high efficiency. In this study the finite
element analysis of residual stresses in shielded metal arc
welding of two similar plates is performed with the
ANSYS software. This analysis includes a finite element
model for the thermal and mechanical welding
simulation.
Index Terms—Clamp location, Finite Element Analysis,
SMAW, Welding distortion.
I. INTRODUCTION
Arc welding is an effective an economic joining
method to produce high strength welded structures.
Due to the non-uniform expansion and contraction of
the weld metal and surrounding base metal by heating
and cooling cycles during welding, thermal stresses
occurs in the weld and the adjacent areas. These
stresses cause welding distortion.
Correction of distortion often requires additional after-
weld reworks, which are usually costly and time
consuming process. The best practice to minimize or
control distortion is proper welding process design.
Computer simulation tools based on numerical
methods are very useful to predict welding distortions
and residual stresses at the early stage of product
design. Finite element method (FEM) has been the
most popular and powerful tool for simulating the
thermo-mechanical behavior of a structure during
welding process.
IJIRT 144223 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY
By proper amount of restrained force welding
distortion can be considerably reduce. Results of FEM
gives the ideas of location of clamp and clamping
force.
II. LITERATURE SURVEY
1. Amin Esmaeilzadeh, Mohammad Sadeghi,
Farhad Kolahan [1]
A thermo-elastic-plastic finite element model is used
to predict the behavior of welded thin plate during butt
welding.The finite element model is close to actual
welding process. Results show that the proposed
welding simulation can accurately predict temperature
history and thermal buckling during the welding. It is
shown that proper fixture positions can control the
welding distortions with great efficiency.
2. Nadeem Ullah Dar, Ejaz M. Qureshi, M.M.I
Hammouda [10]
Along and near the weld line, a high tensile and
compressive axial residual stresses occur on the
cylinder inner and outer surfaces, respectively. Hoop
residual stresses are sensitive to the angular location
from the weld start position. Maximum axial and
radial deflection is observed near the weld line. The
axial shrinkage decreases continuously away from the
WL and a minimum shrinkage is shown at the
restrained end. However, on the restraint-free end
some deflection (face tilt) is observed.
3. C. Liu, J. X. Zhang [5]
The interaction among worktable, welding plate and
fixture can be simulated with the three-dimensional
multibody coupling FEM. The angular distortion
decreases quickly with increasing initial restraining
moment until the restraining moment comes to a
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threshold. The welding distortion can be fully
restrained with a specified restraining force located at
a minimum distance from the weld line center.
However, the welding plate would spring back to some
content after the restraining force release.
4. S. M. Ahir, N.B. Patel, K. A. Patel [14]
Signal to Noise(SN) ratio is increase as increase in
welding speed, decrease with increase in current, and
increase to some point then after decrease with
increase V groove angle. Parameter Angle has major
effect of weld distortion then current and then speed.
Current contributes 29.23%, Angle contributes
41.52%, Welding speed contributes 14.19%.
5. Dragi Stamenković, Ivana Vasović [6]
Result shows that, after welding is completed the
residual stress in max. on the weld line and near the
weld line (0 to 0.01 m), between 0.01 to 0.05 m to weld
line it is min., and after that it has some value. The
present results obtained by the finite element method
are very close to the experimental results.
6. Mr. SachinS. Rathod, Prof. S. P. Gaikwad, Prof.
N. S. Katikar [8]
With increase in heat input the displacement and strain
increases whereas the residual stress decreases.
Increase in speed, results in a significant increase in
displacement and strain whereas the residual stress is
decreases. Complex welding phenomena can be
simulated using a commercial Finite Element package,
viz., ANSYS. Special features of birth and death
element has been used to simulate the deposition of
weld material. Based on the simulation result,
distortion or shrinkage of weldment can be predicted
numerically.
7. Sandeep Duhan, Ashwani Mor, Deepak Malik [13]
Increase in current and time gap increases angular
distortion and increase in length of plate and dia. of
electrode decrease angular distortion. The highest
effect on angular distortion is observed on diameter of
the electrode using within the design range of
parameters. The least effect on angular distortion is
observed of time between successive passes using
within the design range of parameters.
8. Rehan Waheed, Abdul Shakoor [11]
IJIRT 144223 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY
The predicted results of welding distortion and
residual stress are in quite agreement with actual
measured values. In thin metal plates buckling
distortion is dominant. Temperature dependent
properties play a vital role in predictionof welding
induced distortion.
9. Reenal Ritesh Chand, Ill Soo Kim, Qian Qian Wu,
Bong yong Kang and JiYeon Shim [12]
There is a change in temperature gradient through the
plate thickness as the plate thickness is increased in
butt welding. Restraining the plate has a large effect
on the distribution of residual stress and deflection. It
could be generalized that factors such as residual
stress, deflection and plate strain is mainly dependent
on the peak temperature and restraining conditions that
are applied on the plate. The welding direction and
welding speed has also some effect on residual stress,
the large magnitude of stress is noted at the edges
compared to across the mid-way of the plate, this is
due to the start edge having more cooling time
compared to the ending edge.
10. M. Seyyedian Choobi, M. Haghpanahi1 and M.
Sedighi [9]
Clamping during welding and cold releasing after
cooling to ambient temperature reduces final angular
distortions, significantly. Clamping during welding
and cold releasing after cooling to ambient
temperature increases transverse residual stresses.
Clamping during welding and cold releasing after
cooling to ambient temperature increases longitudinal
residual stresses at the bottom surface of the plate.
Clamping during welding and hot releasing after
welding does not affect the magnitude of deflections
or residual stresses.
11. K-Y Bae [7]
The theoretical simulations showed that even low
elastic pre-straining loads could reduce the residual
angular distortion by assisting a large thermal
distortion during heating and prohibiting the reverse
distortion during cooling. The small deformation
theory can also accurately predict the distortion of the
fillet joint in the free-end condition with a low pre-
straining load. However, the large deformation theory
should be used for the accurate prediction of the
distortion of the fillet weldment in the constrained-end
condition. By comparing the distortions predicted by
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the analysis with those obtained by experiment, it can
be seen that the large deformation theory can better
describe the deformation phenomenon during fillet
welding than the small deformation theory.
12. A. V. Damale, Dr. K. N. Nandurkar[3]
Experimental temperature distributions of the “V” butt
joints away from the weld line closely matched the
values obtained from the finite element modelling.
Layer-wise application of heat flux, incorporation of
the joint geometry into the modelling and
consideration of filler material deposition in the
analysis led to temperature distribution profiles that
closely matched the experimental values. Close
matching between modeled and measured angular
distortions has been observed. Predicted angular
distortion can be used for pre-setting the specimen to
control the angular distortion.
13. B Q Chen, M Adak and C Guedes Soares [4]
Heating speed, heat input and plate thickness were
proved to have a significant impact on the welding
response. Higher heat input / lower heating speed /
thinner plate will result in higher temperature and
bigger deformation. Those parameters also have effect
on the final deformed pattern of the plate. The restraint
on the model has a critical effect on the simulating
result. However, for certain parameters, the mesh
types and heat source model types turned out to have
a relatively lower effect on the results.
14. A.R. Kohandehghan, S. Serajzadeh [2]
It is observed that application of both fixture and weld
sequence have a significant impact on distribution and
values of longitudinal and transverse residual stresses.
The implementation of welding fixture causes
substantial changes in the distribution of residual
stress as well as increases the maximum transverse
stress about 76% while it decreases the longitudinal
residual stresses. Furthermore, the geometry of the
weld pool changes when the welding fixture is used,
and it caused about 21% decrease in the depth of the
weld pool for the welding conditions used in this
research.
REFERENCES
IJIRT 144223 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY
[1] Amin Esmaeilzadeh, Mohammad Sadeghi,
FarhadKolahan, “Using FEM for Prediction of
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[9] M. Seyyedian Choobi, M. Haghpanahi and M.
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387 394.
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[10] Naeem Ullah Dar, Ejaz M. Qureshi, and M.M.I

Hammouda, “Analysis of weld-induced
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Wu, Bong yong Kang and JiYeon Shim,
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[14] S.M. Ahir, N.B. Patel, K.A. Patel,
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