Computer methods

in applied
mechanics and
engineerlng
ELSEVIER Comput. Methods Appl. Mech. Engrg. 147 (1997) 401-409

Automatic remeshing for three-dimensional finite element

simulation of welding
L.-E. L,indgren”,*, H.-A. Hfiggblad”, J.M.J. McDillb, A.S. Oddy”
“LuleB University of Technology, 971 87 Luled, Sweden
bCarleton University, Ottawa, KlS 5B6, Canada
‘OddylMcDill Numerical Investigation Sciences Inc., Ottawa, Kl G OW8, Canada

Received 17 January 1997; revised 31 January 1997

Abstract

Three-dimensional finite element simulation of electron beam welding of a large copper canister has been performed. The use
of an automatic remeshing algorithm, based on a graded hexahedral element was found to be effective. With this algorithm the
strongly nonlinear thermomechanical effects locally close to the moving heat source can accurately be modelled using a dense
element mesh that follows the heat source.

1. Introduction

Finite element (FE) simulation of welding has been performed for more than twenty years [l-4]. The
early models were only two-dimensional (2D). The first three-dimensional (3D) models were presented
around 1990 [5-71. Fig. 1 shows problem size versus year of publication for [6-131 and current paper.
Despite the increase in problem size during the later years the computational task can be overwhelming
when a good spatial resolution is required in the neighbourhood of the weld. The thermal and
mechanical fields from the welding process have large gradients near the arc. Therefore, it is natural to
apply some remesh:ing techniques as the arc is moving.
This paper presents an application where automatic remeshing of a graded hexahedral element is
utilised. Two models, one with and one without remeshing, that give the same accuracy were used. The
application is a large copper canister that is intended to be used for storage of nuclear waste. It is made
of two halves tha; are-joined by electron beam welding. The aim of-the investigation was to find
residual plastic strains and stresses in order to estimate subsequent creep-damage of the canister
[14,15].

2. Spatial resolutiou required in simulation of welding

The use of a moving, concentrated heat source is common for most welding processes. The
characteristic length can vary from less than a millimetre, in the case of laser welding, up to a couple of
centimetres, in the case of a gas flame. Rykalin [16] represented this by a diagram showing thermal flux

* Corresponding author.

0045-7825/97/$17.00 0 1997 Elsevier Science S.A. All rights reserved

PIZ SOO45-7825(97)00025-X
402 L.-E. Lindgren et al. I Comput. Methods Appl. Mech. Engrg. 147 (1997) 401-409

lE+7

p31

lE+5

1975 1990 1995 1990 1995 moo

YEW
Fig. 1. Size, number of unknowns in mechanical analysis times the number of time steps, of computational models for simulation
of welding. The reference numbers are given in the diagram, * denotes this study.

and source size. This localisation creates a large thermal gradient with corresponding gradients in the
mechanical fields. However, this is not the sole factor determining the required minimum size of the
finite elements. It is also determined by the scope of the investigation. If the effect of the residual
stresses and deformations on the subsequent use of the component is the focus, then it is possible to use
a coarser mesh than if hot cracking is studied. It may be enough to have a few elements in the
heat-effected zone (HAZ) in the first case. However, it may turn out that many elements are needed,
requiring element sizes as small as 50 microns as in some laser welding applications [17]. On the other
hand, the computational model must be large enough to give correct boundary conditions for the
thermal and mechanical fields. The latter is more demanding due to the elliptic nature of the quasistatic
thermal stress problem. The combination of a model including small elements that are part of a finite
element model of a large structure is further complicated by the motion of the heat source. The domain
with large gradients is moving. The obvious solution to this is to have a mesh with a fine region that is
moving with the heat source. This basic approach was utilised by Rosenthal [18] who used a coordinate
system fixed relative to the heat source. A co-moving frame applied in a finite element analysis of a
process with moving heat source was used by Bergheau et al. [19]. Brown et al. [20] used dynamic
substructuring where a denser mesh was travelling with the heat source on an overall coarser mesh.
Linear hexahedral elements are superior to linear tetrahedral elements [21,22]. They are also better
than quadratic tetrahedron elements when plastic deformation occurs [22]. However, most analyses
involving remeshing use tetrahedron elements. This is due to the good availability of procedures for
generating arbitrary graded meshes using tetrahedral elements. The models in this work are based on a
graded hexahedron, described in the next section, that alleviates the creation of a mesh with a refined
region. The element is combined with a remeshing strategy that makes it possible to move the refined
region with the heat source.

3. Remeshing of graded hexahedron

It is well known that h-adaptive techniques are preferable wherever the solution is rough; i.e., the
gradients are not continuous [23]. The h-adaptive strategy used here follows the techniques developed
by McDill and co-workers [24-271. The method has three components, the basic grading hexahedral
 L.-E. Lindgren et al. I Comput. Methodc Appl. Mech. Engrg. 147 (1997) 401-409 403

elements [24], the adaptive remeshing technique [25,26], and the data transfer between meshes [27].
The h-adaptive strategy was selected because of the nature of the temperature, stress and micro-
structure fields involved in welding. Although continuous, these fields may not always vary smoothly
because of the temperature dependence of material properties as well as internal boundaries caused by
phase transformations and plasticity. These internal boundaries are physically manifested as HAZ
boundaries and plastic zone boundaries. In addition, singularities such as crack tips, re-entrant corners
and point loads are better captured with h-adaptive schemes unless special singularity elements are
used.

3.1. Grading hexahedron elements

The technique is built around the 8-26 node grading hexahedron originally described in [24]. This is a
variation of the familiar linear element in that temperatures or displacements vary linearly with position
within each element. It can be extended to a quadratic, non-conforming grading hexahedron as in [28]
for use in welding analyses [13] but this form has not been used in this investigation. The structure of
the element requires eight mandatory corner nodes (see Fig. 2). Nodes 9 to 20 are optional, located at
the mid-edges and nodes 21 to 26 are optional mid-face nodes. These optional nodes may be included in
any combination. The presence of a mid-face node modifies the basis functions of existing mid-edge
nodes and corner nodes present on that face. Mid-edge nodes modify the basis functions of the corner
nodes on that edge. This preserves interelement continuity. The basis functions are shown in Table 1.
The table should be evaluated, in decreasing order, from Nz6 to N,. If a node is not present, its basis
function and all subsequent references to it should be removed from the table. The element is divided
into, at most eight, linear subdomains, depending on the arrangement of mid-edge and mid-face nodes.
Numerical integration occurs over each subdomain. The net result is very similar to the assembly of a
collection of standard linear elements with some degrees-of-freedom condensed out. However, by
embedding the constraints in the basis functions, all nodes are active. Global constraint equations,
matrix condensation operations and additional data structures to identify redundant nodes are not
required.
These elements have proven to be computationally very effective, especially around point loads and
weak singularities such as welding heat sources. As described in [24], a point thermal load in an infinite
half space has a singularity proportional to the inverse of the radial distance. For a cubic domain with
the point load at one corner, if 12is the ratio of the size of the cube to the size of the smallest element
then the number of elements in a standard, uniform mesh is n3. In a recursively graded mesh only
7 *log,(n), that is 7 times logarithm base 2 of IZ, elements are required to obtain elements of a similar
size near the singularity. This grading has been the key to successful 3D thermal-mechanical finite
element analysis of welds since it allows an easy concentration of elements and nodes around the
welding source where gradients change rapidly.

3.2. Adaptive remeshing technique

The structure of the grading hexahedrons led to an adaptive remeshing strategy as described in
[25,26]. It allows easy modifications to be made in the mesh by adding extra nodes and subdividing
elements only in regions where it is required. Element division into octants preserves shape regularity

Fig. 2. The eight to twenty-six node, grading hexahedron element.

404 L.-E. Lindgren et al. I Comput. Methods Appl. Mech. Engrg. 147 (1997) 401-409

Table 1
Basis functions

26 0.5(1- kl)U - lbm- 0

25 O-5(1- kl>(1- /d)(1 + 5)
24 w1 - 121)(1-17)(1- Irl1
23 031 - ml +7fx1- Irl>
22 0.5(1 - 5x1 - lM1 - 14%
21 0.5(1+ S)(l- lb7lN- lil)
20 o.q1+ 5X1-71)(1- IiD - 0.5(& + K,)
19 0.25(1-t)(l-q)(l-Iii)-0.5(&z+&)
18 0.25(1- <)(I +v)(l - kl) - 0.5@‘,, + k)
17 0.25(1 + E>(l +rl)(l - I&/) - 0.5(&, + f%)
16 0.25(1 + 5)(1 - b11)(1- 5) - 0.5(N,, + N,,)
15 0.25( - IS[)(I - v)(l - J-) - 0.5(%, + W
14 0.25(1- [)(I- Ivl)(l - %I- O.W, + N,,)
13 0.25(I - kl)(l+~)(l- 0 -0.5(&x + N,,)
12 Q.25(1 + 5)(1- b11>(1+ l) - 0.5(&, + KS)
11 0.25(- [[I)(1 -77)(1+5)-0.5(N,,+N,,)
10 0.25(1- 5)(1- hl)(l + 5) - 0.5(N,, + N,,)
9 0.25(f - ISl)(l +d(l + 5) - 0.5(N,, + K,)
8 0.125(1+ 5)(1 -v)(l -i) - 0.25(N,, + Nz4 + N,,) -0.5(N,, +N,6 + Nm)
7 0.125( 1 - .$)(l - v)(l - J) - 0.25(N,, + A’,, •t N,,) - 0-5(N,, + N,, + N,,)
6 0.125(1 - 5)(1 + v)(l - 5) - 0.25(N,, + Nz3 + N,,) - 0.5@‘,, + N,, + N,d
0.125( 1+ t)( 1 + v)( 1 - 5) - 0.25@‘,, + h’z3 + N,,) - O-5@‘,, + N,, + N,,)
4 0.125(1+5)(1 -v)(l + 6) -0.25@‘,, + Nu +N& -0.5(N,, +N,, +Nx,)
3 0.125( 1 - .$)( 1 - q)( 1 + i) - 0.25(&, + Nz4 + N,,) - 0.5(N,, + N,, + N,,)
2 0.125(1 - t)(l + TJ)(~+ 5) - 0.25(N,, + h’>x+ N,,) - 0.5(N, + N,, + N18)
0.125(1 + [)(l +r,)(l + r) -0.25(&, + N,, f IV,,) -O-5@& + N,, + N,,)

but is not an essential requirement. This retains the basic mesh and changes are localized. Simple array
type data structures identify the elements attached to corner, mid-edge and mid-face nodes are all that
are required for automatic refinement. Coarsening; i.e. the replacement of many small elements with
fewer large elements is also possible. The element assembly technique in [26] eliminates the need to
store or retrieve the former topology. Either fully arbitrary [26] or tree-type coarsening strategies are
possible. In this application coarsening returns the mesh to a former configuration by retracing the
refinement path. A tree structure which identifies the central nodes at each refinement level is used to
retrace the path. The rules and operations followed in refinement and coarsening are described in
[25,26]. Briefly, bisection refinement and binary grading preserve shape regularity and avoid abrupt
transitions from coarse to fine regions. Refinement propagates to neighbouring elements. Coarsening is
not permitted to propagate to neighbours and only occurs if all members of a local group allow it and if
it results in a valid mesh. Only redundant, i.e. unnecessary, nodes are eliminated.
The creation of new meshes with refinement in some areas and coarsening in others changes the
topology of the mesh. This changes the number and locations of nodes and Gaussian integration points.
In time dependent problems information associated with nodes and Gauss points must be transferred
from the old mesh to the new mesh. If this is not done with some care it is quite possible that the
transfer will introduce errors in the temperature, stress and plastic strain fields. This changes the total
energy in the system which may be thermal energy in the form of temperatures, elastic energy as
stresses, or energy dissipated as plastic work. The data transfer from the old to the new mesh depends
on whether there is coarsening or refining of the mesh and if it is nodal data or Gauss point data.
Interpolation is used for nodal data and Gauss point data in refinement. The coarsening procedure is
somewhat more complex than the refining procedure as the coarser mesh can only approximately
represent the old, finer mesh. It was decided to use a least-square method based on a local domain for
transfer of nodal data. Gauss point data were transferred by interpolation. See [27] for details.
 L.-E. Lindgren et al. I Comput. Methods Appl. Mech. Engrg. 147 (1997) 401-409 405

3.3. Measures for determining element sizes

In this investigation a simple geometric measure; h/r where h is the size of the element and r is the
shortest distance from the element centre to the path of the heat source until next remeshing is
performed, was used to drive the refinement and coarsening. This makes it possible to refine in advance
of the motion of the heat source. The user can then choose an optimal combination of the amount of
refinement /coarsening each time and how often this should be performed. Refinement or coarsening
decisions are ideally driven by error measures based on the solution and the thermal, stress and
microstructural fields present. In the future, generic error measures such as [29] which can evaluate the
error in the temperature, stress, plastic strain or microstructure fields will be used to determine which
elements to refine or coarsen. A posteriori measures of this type can only change the mesh once a trial
solution is available. With a moving heat source, as is found in welding analysis, it would be a distinct
advantage to alter the mesh in response to the source motion before generating a solution at each step.

4. Longitudinal butt welding of a copper canister

4.1. Background

In the Swedish nuclear waste program it has been proposed that spent nuclear fuel shall be placed in
composite copper-steel canisters. These canisters will be placed in holes in tunnels located some 500 m
underground in a rock storage. The canister consists of two cylinders of 5 m length, one inner cylinder
made of steel and one outer cylinder made of copper. The outer diameter of the canister is 500 mm and
the wall thickness is 50 mm. For storage, the steel cylinder, which contains the spent nuclear fuel, is
placed inside the copper cylinder. Thereafter, a copper end is butt welded to the copper cylinder using
electron beam weld:ing. The primary objective in the mechanical design of the canister is to ensure no
leakage of radioactive particles to the surroundings. One of the alternative fabrication schemes for the
outer copper cylinder is based on cold forming (rolling) and subsequent longitudinal seam welding of
the two copper half cylinders.

4.2. Computational models

The potential of the proposed algorithm is demonstrated by studying the longitudinal butt welding of
two copper half cylinders previously studied in [15]. The models used do not include residual stress
from the rolling process. The transient and residual temperature, stress and strain fields present in the
canister during longitudinal seam welding and after cooling to ambient temperature are calculated
numerically by use of the coupled thermo-mechanical FE-code SIMPLE [30]. Due to symmetry the
FE-model consists of one half of a copper half cylinder. The models extend 500 mm in the axial
direction including the rear end where the welding finishes. The cylinder is restrained axially at the
front end, the rear lend is free. In order to have a satisfying accuracy in the simulations, the elements
close to the weld-path must be around 5 mm in size, transverse to the welding direction. Two models
are used: one with and the other without remeshing. The meshes were chosen in order to achieve about
the same accuracy. The thermal material data for the copper alloy were taken from handbooks (see [8]
for the data used). A thermo-elastic-plastic model with linear isotropic hardening is used in the
mechanical analysis. The material data for the mechanical analysis were determined from uniaxial
tensile tests. See [15] for the elastic and plastic material data used. The load is applied by defining a
moving box along the cylinder. In each loading-step the nodes in the box and those passed by the box
are subjected to a uniform input of energy. The net heat power is 8 kW and the welding speed is
5 mm/s. The loading is applied during the first 100 s of the simulation which is performed in a total of
1000 s. Both calculations are performed in 324 loading-steps. The FE-model without remeshing consists
of 5783 nodes and 4220 eight-node brick elements. To reduce the number of elements in the model
without reducing the accuracy a dense mesh is required in the vicinity of the moving heat source but a
406 L.-E. Lindgren et al. I Comput. Methods Appl. Mech. Engrg. 147 (1997) 401-409

coarser mesh is used elsewhere. See Fig. 3(b) for the FE-mesh of the non-remeshing model. The
FE-model used for remeshing consists initially of 1000 eight-node brick elements (1683 nodes) but
increases to maximum 2715 elements (441 nodes) at 70 s. The remeshing is performed nine times. See
Fig. 3(a) for the FE-mesh at different stages of the calculation.

4.3. Computed temperatures and stresses

The two FE-calculations, without and with remeshing, were performed on an IBM RS6000, model
590. The calculation without remeshing required 34 h and 20 min. of CPU-time. The CPU-time for the
model with remeshing was 14 h and 5 min. The size of the stiffness and the conductivity matrix of the
non-remeshing model totals 9.7 million terms. The corresponding size for the remeshing model varies
from 1.6 to 5.3 million. The evolution of the calculated axial stress is shown in Fig. 3. The plastic strain
fields at the final stage are shown in Fig. 4. Comparison of the residual stress-states is shown in Fig. 5.
The temperature at 50 s (when the beam is half-way along the cylinder) is shown in Fig. 6. The

Fig. 3. Comparison of the axial stress field (z-stress). (a) With remeshing at 10, 50, 100 and 200 s; (b) without remeshing at 50 and
100 s.
 L:,E. Lindgren et al. I Comput. Methods Appl. Mech. Engrg. 147 (1997) 401-409 407

mill I 0.0 mh=o.o

nnx=o.o3e mLx=O.OU

a) W
Fig. 4. Comparison of the residual effective plastic strain. (a) With remeshing; (b) without remeshing.

Fringe Iev6l6 [MPal

60

75

69

64

59

53

48

43

37

32

27

21

16

11
min. 1.95 MPrI mm * 1.65 f4Pe
llWXE61.8MPB mar Ia%5 MP.¶ 5

15
a) W
Fig. 5. Comparison of the residual effective stress (von Mises). (a) With remeshing; (b) without remeshing.

maximum temperature at the nodes in the centre of the weld pool reach approximatively the melting
temperature, 1083°C. However, the used postprocessor plots element average temperatures resulting in
a maximum temperature of 520°C in Fig. 6.

4.4. Comparisons of computational models

As can be seen in Figs. 3 to 5, the simulation using remeshing gives similar results to the simulation
without remeshing. The reduction in size of the models decreases the required CPU-time. It also
reduces the data-storage requirement substantially, this can in some applications be the key factor
determining whether a successful FE-simulation can be completed or not.
408 L.-E. Lindgren et al. I Comput. Methods Appl. Mech. Engrg. 147 (1997) 401-409

Fig. 6. Temperature distribution at 50 s.

5. Discussion and conclusions

The automatic remeshing procedure is found to be effective. The required CPU-time was reduced by
60% for the studied application without any loss in accuracy. Larger gains will be expected for
application with longer welds as the zone associated with large gradients will be smaller relative to the
total length of the weld. The current logic for deciding the size of the elements in relation to the
distance to the arc will be combined with a posteriori error measure, in order to have a versatile tool
that includes a predictive capability.

Acknowledgements

This work was funded by the Swedish Nuclear Fuel and Waste Management Co (SKB) in Stockholm,
Sweden and by Lulei University of Technology, Lulea, Sweden.

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