Welded Structures
A Battelle Joint Industry Project (JIP) was launched in 2001 to further refine and validate Battelle’s patented mesh-insensitive structural stress method for various industrial applications. As a result of the JIP sponsorship, rapid progress has been made in validating the effectiveness of the structural stress method by effectively correlating large amount of S-N data from drastically different joint types, loading modes, and plate thicknesses.
Your Challenge
Math-Based Manufacturing Welding remains as one of the primary fabrication and assembly processes in industry. With today’s increasing demands for higher product quality and manufacturing cost reductions, math-based rapid virtual prototyping techniques that can integrate materials, manufacturing, product design and performance requirements have become essential. Factors such as material weldability, welding-induced residual stress, distortion, weld property variation, as well as weld design parameters, all impact the actual performance of welded structures. Today’s commercially-available CAE/CAM simulation tools however are not adequate in addressing some of these important welding-related manufacturing concerns.
Our Solution
Virtual Welding Laboratory Over the last decade, Battelle’s Center for Welded Structures Research has developed a unique suite of advanced computational simulation tools. These tools have been proven to be highly effective in not only trouble-shooting on the production floor, but also as a new product development tool in the areas of weld design optimization, weldability, characterization, welding procedure development, and performance evaluation.
The Battelle Difference
Fully Integrated Simulation Tools and Well-Known Expertise All of Battelle’s unique computational tools are fully integrated in a modular format to allow portability and a smooth interface with commercial finite element codes. They can be used along with Battelle’s well-known design and manufacturing expertise in an cost-effective manner to address manufacturing and/or design concerns associated with both solid-state joining and fusion welding processes, e.g.:
- Solid-state joining processes (resistance welding, friction/inertia welding, friction stir welding, etc.): Novel electrode design, process parameter optimization, residual stress/distortion mitigation, weld performance prediction and optimization, etc.
- Arc welding and high-energy beam welding: weld design, fixturing design, weld pool modeling for monitoring/control, residual stress/distortion mitigation technique, optimum weld sequencing development
- Optimum joint design and performance evaluation: Fatigue-resistant joint design, fatigue life prediction methodologies, fracture control, and fitness-for-service assessment techniques incorporating advanced residual stress techniques, mechanical and thermal stress improvement techniques, including optimized PWHT and L-PWHT, etc.
Interactions of sequential manufacturing processes can be accounted for by considering detailed interactions among various sequential manufacturing processes for a specific application. Such total manufacturing process effects on structural performance could then be evaluated either at a local weld detail or at a global level for optimized structural performance.
This page was printed from:
www.sdas.battelle.org/verity/weldmodeling.aspx
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What Industry is Saying
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"Other fatigue software vendors claim to have an effective method,
but when you look into the details, they're using a lot of subjective
'fudge factors,' not Pingsha"
Hari Agrawal,
Senior Technical Specialist with Ford Motor Co.
"Incredibly significant and compares its impact on engineering to that of mapping the human genome in the scientific world."
Tarsem Jutla,
Caterpillar
"It will change the way fatigue analysis is taught at universities and practiced by industry."
Pedro Vargas,
ChevronTexaco
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