Bu araştırma, kaynak sebepli olabilecek distorsiyonları tahmin etmek için sayısal bir simülasyon ile bunun deneysel doğrulamasını sunmaktadır. 3mm, 5mm ve 8mm kalınlığındaki S355J2G3 yapı çeliğinden üç deneysel numune test edilmiştir. Simülasyon, SYSWELD programında yer alan gaz metal ark kaynağı (GMAW) ile tasarlanmış olup, ısı kaynağı Goldak’ın çift elipsoidal dağılımı ile modellenmiş ve hesaplamalarda doğrusal olmayan ısı transferi analizi kullanılmıştır. Sonuçları doğrulamak içinse tek köşe kaynaklı T-bağlantılarında meydana gelen bozulmaları analiz etmek üzere bir deney düzeneği kurulmuştur. Bu çalışmada, artık gerilmeleri ve açısal bozulmaları değerlendirmek için sonlu elemanlar (FE) yöntemi kullandı. Kesitlerdeki penetrasyon derinliğini, kaynak sonrası oluşan açısal bozulmaları, sıcaklık dağılımını ve artık gerilmeleri değerlendirmek için bir dizi FE simülasyonu ve ilgili deneyler gerçekleştirilmiştir. Deney sonuçları, kaynak işlemi henüz yapılmadan simülasyonlar yoluyla prosesin kontrol edilmesinin hem bozulmaları en aza indirmeye hem de maliyetli tasarım hatalarını azaltarak kaynak performansının artırılabileceğini göstermiştir.

Anahtar Kelimeler:

Kaynak deformasyonu, artık gerilme, T-bağlantı kaynağı, sonlu elemanlar yöntemi

Finite Element Simulation and Experimental Validation of Welding Distortion of Fillet Welded T-joints

This research presents a numerical simulation for predicting welding induced distortion with an experimental validation. Three experimental specimens of S355J2G3 structural steel with thicknesses of 3mm, 5mm and 8mm have been used as test cases. In order to validate the results an experiment was set up to gain detailed information about distortions occurring in single fillet welded T-joints. The non-linear heat transfer analysis is used and heat source is modeled with the Goldak’s double ellipsoidal distribution by using SYSWELD in the gas metal arc welding (GMAW) process. This study employs the finite element (FE) method to evaluate residual stresses and angular distortions. A series of FE simulations and corresponding experiments are performed to evaluate the depth of penetration in the cross sections, angular distortions that occur after welding, temperature distribution, and residual stresses. A coordinate measuring machine and a 3D non-contact scanning device are used to measure the angular distortions and displacement distributions, respectively. The results show that controlling welding process via simulations can significantly enhance the performance of process, and help to minimize distortions and decrease costly design errors.

Keywords:

Welding distortion, residual stress, T-joint fillet weld, finite element model,

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