Three Dimensional Simulation of Robot path, Heat Transfer and Residual Stresses of a welded Part with Complex Geometry

摘要

In this article a simulation system is presented that combines computer aided robotics software used to define the welding operation, with a finite element model that predicts temperature-time histories and residual stress distributions for welding applications. The objective is to develop a tool for engineering processes in which robot trajectories and welding process parameters can be optimized off-line on parts with complex geometries. The system was evaluated on a stainless steel gas turbine component. Temperature dependent properties and phase change were included in the analysis. The turbine component was welded using an in-house TIG welding cell. The assumptions and principles that underpin the modeling techniques are presented together with predicted temperature histories, residual stresses, and fixture forces. Predicted residual stresses were compared with neutron diffraction measurements.