Tiêu chuẩn iso ts 18166 2016

© ISO 2016 Numerical welding simulation — Execution and documentation Simulation numérique de soudage — Exécution et documentation TECHNICAL SPECIFICATION ISO/TS 18166 Reference number ISO/TS 18166 20[.]

Numerical welding simulation —

Simulation n mérique de souda e — Ex c ution et documentation

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F reword v

1 Sc ope 1

2 Nor mati ve r eferenc es 2

3 Terms and definitio s 2

4 Des riptio of the pr oblem 3

4.1 General 3

4.2 Simulation o je t 4

4.3 Simulation o je tives 4

4.4 Physical model 4

4.5 Mathematical model an solution method 5

4.6 Implementation 5

5 Wor kflow 5

5.1 General 5

5.2 Simplfications an as umptions 6

5.2.1 General 6

5.2.2 Mate ial pr ope ties 6

5.2.3 Model scale an sco e 6

5.2.4 A nalysiscoupl ng 6

5.3 Pr oc s desc iption an p ramete s 7

5.4 Structur e and weld g eometries 7

5.5 Mate ials 7

5.5.1 General 7

5.5.2 The mo-physical mate ial prope ties 7

5.5.3 The mo-me hanical mate ial pr ope ties 7

5.6 L ads an b u dary con itions 7

5.6.1 General 7

5.6.2 The mal 7

5.6.3 Me hanical 8

5.7 Result r eview 8

5.8 Reporting 8

6 Valdatio and ver ification 8

6.1 General 8

6.2 Ve ification of the simulation model 8

6.3 Calbration of the model p r amete s 8

6.4 Plausibi ty che k of the simulation r esults 9

6.5 Valdation of the simulation r esult 9

6.5.1 General 9

6.5.2 Valdation ex pe iment g uidelnes 9

7 Repor ting /display of r esults 9

7.1 General 9

7.2 Simulation o je t 9

7.3 Mate ial pr ope ties and input data 1

7.4 Pr oc s p ramete 1

7.5 Meshing 1

7.6 Nume ical model p ramete s 1

7.7 A nalysis of r esult .1

A nne x A (informative)Documentation template 11

A nne x B (informative)Modeling of he t tr ansfe during welding 12

A nne x C (informative) Valdation ex per iment g uidelnes 14

A nne x D (informative) Mo eling of r esidual stres es 16

A nne x E (informative) Distor tion pr ediction 17

Biblog raph y 19

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ele trot ech ical s an ardization

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The committ ee r sp nsible for this document is ISO/TC44, Weldin a d al ed proc es s es

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Numerical welding simulation — Execution and

This Te h ical Spe ification pro ides a workflow for the ex ecution, v ldation, ve if ication an

documentation of a n me ical welding simulation within the f ield of computational welding me hanics

(CWM) As such, it primariy ad r s es the mal an me hanical f init e element analysis (FEA) of the

fusion welding ( e ISO/TR 2 90 :2 0 , 2.1 5)of metal p rt an fa rications

CWM is a bro d an growing ar a of engine ring analy sis

This Te hnical Spe ification covers the folowing aspe t and r sult of CWM, ex clu ing simulation of

the proc s it elf:

— heat flow d ring the analy sis of one or mor p s es;

— the mal ex ansion as a r sult of the heat flow;

— the mal s r s es;

— develo ment of inelas ic s rains;

— efe t of t empe atur on mat erial pro e ties;

— pr dictions of r sid al s r s dis ributions;

— pr dictions of welding dist ortion

This Te hnical Spe if ication r fe s t o the folowing phy sical efe t , but these ar not co e ed in depth:

— phy sics of the heat our e (e.g lase or welding ar );

— phy sics of the melt p ol (an key hole for p we beam welds);

— c eation an r t ention of non-eq i ibrium sold phases;

— solution an pr cipitation of se on phase p rticles;

— efe t of mic os ructur on mat erial pro e ties

The guidanc given b this Te h ical Spe if ication has not be n pr p r d for use in a spe if ic in us ry

CWM can be benef icial in design an as es ment of a wide rang e of comp nent It is anticip t ed that

it wi l ena le in us rial b dies or comp nies t o def ine r q ir d levels of CWMfor spe if ic a plcations

This Te h ical Spe if ication is in epen ent of the sof war an implementation, an the efor is not

r s rict ed t o FEA, or t o any p rticular in us ry

It pro ides a consist ent ramework for-primary aspe t of the commonly ado t ed methods an g oals of

CWM ( inclu ing v ldation an ve if ication t o alow an o je tive ju gment of simulation r sult )

Through pr sentation an desc iption of the minimal r q ir d aspe t of a complet e n me ical welding

simulation, an introd ction t o computational welding me hanics (CWM) is also pro ided (Ex mples

ar pro ided t o i us rat e the a pl cation of this Te h ical Spe if ication, w hich can furthe aid those

int er st ed in develo ing CWM compet ency)

Clause 4 of this Te h ical Spe if ication pro ides mor detaied information r lating t o the g ene aly

v ld simulation s ructur an t o the cor espon ing a plcation Clause 5 r fe s t o cor esp n ing

p rt of this Te h ical Spe ification in w hich the s ructur for the r spe tive a plcation cases is put

in conc et e t erms an ex mples ar given An ex A pr sent a documentation t emplat e t o promot e the

consist ency of the r p rt ed simulation r sult

2 Normati ve referenc es

The folowing document , in w hole or in p rt, ar normatively r fe enc d in this document an ar

in ispensa le for it a pl cation F or dat ed r fe enc s, only the edition cit ed a pl es F or u dat ed

r fe enc s, the lat es edition of the r fe enc d document ( inclu ing any amen ment )a pl es

ISO/TR 2 9 1, Weldin a d r lated proc es ses — Voc ab lar y

3 Terms and definitions

F r the purp ses of this document, the te ms an definitions giv en in ISO /TR 2 90 and the

fol owing a ply

3.1

bo ndary co ditio s

con itions imp sed at the sp tial b u dary of a computational model that desc ibe the int eraction

between the modeled an u modeled domains

Not e 1 t o entry: Complete b u dary con itions provide a u iq e solution t o the specif ic mathematical pro lem

model comprising the u de lying es ential mathematical eq ations inclu ing the a pro riat e initial

an boun ary con itions

ful ar a of the phy sical proc s t o be simulat ed an b u dary an initial con itions r lev nt t o the

simulation o je t as wel as ado t ed simplf ications an as umptions

3.6

plausibi ity check

che k of the o tained calculation r sult in r spe t of their conformity with b sic phy sical principles

3.7

simulation mo el

combination of the phy sical, g eometrical an mathematical models an the solution method

3.8

spatial dis retization

dis ribution an ty eof the g eometric u it for subdividing the g eometric model

3 9

temporal dis retizatio

st epsiz an n mbe of time u it for subdividing the d ration being modeled

val datio

proc s of det ermining the degr e t o w hich a model is an ac urat e r pr sentation of the physical

pro lem from the pe spe tive of the int en ed uses of the model

3.1

val datio ex eriment

ex e iment designed spe ificaly for v ldating the simulation r sult taking ac ount of al r lev nt

data an their u c rtainty

proc s of adjus ing model ng paramet er v lues in the simulation model for the purpose of impro ing

a r ement with r la le ex e imental data

subset of n me ical simulation an analysis of welding

4 Desc iption of the problem

Computational welding me hanics is a subset of n me ical simulation an analy sis of welding that is

primariy ac ompl shed through use of the finit e element method Nonl near the mal an me hanical

analy ses ar pe formed, w hich can be seq entialy or fuly coupled, w he e the welding p we is

a pled t o the computational model in some wa , an the r sulting transient t empe atur (an p s ibly

mic os ructur ) f ields ar then combined with me hanical mat erial pro e ties/ models an b u dary

con itions t o pr dict the s r s an s rain in the model an it dist ortion This desc iption is not

int en ed t o be al inclusive or r s rictive, but is pro ided t o es a lsh the ty ical ex e t ed use t o w hich

this Te hnical Spe if ication might a ply

This Te h ical Spe if ication ad r s es the g ene al CWM pro lem, w hich can be def ined as a thr

e-dimensional sold element model emplo ing a tra el ing powe density heat sour e with simultaneous

calculation of t empe atur , mic os ructur an displac ment, uti zing elast o-visco-plas ic cons itutive

models b sed on mat erial pro e ties ranging from ro m t empe atur t o bey n the melting

t empe atur

This does not pr clu e use of simplf ied methods, but rathe pro ides a simulation method benchmark

from w hich simplf ications can be ju g ed The ne d for simpl f ications ar primariy driven b

computational lmitations ( iz an spe d), an a ply t o many in us ry pro lems, such as hea y se tion

welds in the pr s ur ves el or ship uiding in us ries As any simplf ication of the mathematical

model that r pr sent the phy sical sy st em ma inc ease u c rtainty in the simulation r sult , this

shal be count erb lanc d with mor efort in ve ification an v ldation of the model Not e that al

computational models r q ir ve if ication an v ldation, an this subje t is ad r s ed in gr at er detai

in Clause 6 The pr c ding discus ion is formalz d and ex an ed up n in the r maining subcla uses

4.2 Simulation object

The f irs it em comprises the ex ct desc iption of the comp nent or o e al s ructur , r spe tively, t o be

inves ig t ed (e.g g eometry, se vic con itions), of the emplo ed b se and file mat erials, of the welding

proc d r an p ramet ers, of the a pled welding seq enc as wel as of the r s raint con itions

Optional y, a complementary gra hical r pr sentation or phot ogra h ma be at ached

4.3 Simulation objecti ves

This it em conc rns the def inition of the desir d simulation r sult w hich ensue from the r al task at

han This is p rticularly imp rtant sinc many r al s ic pro lems s i l r q ir simplfication in orde

t o be analy sed with r asona le efort

Ex mples inclu e the calculation of welding r sid al s r s es an / r dist ortions, the as es ment of the

heat afe t ed zone an it charact eris icsor the welding proc d r net heat input

In ad ition, the ultimat e aim should be s at ed t o w hich the desir d simulation r sult ar int en ed t o

be furthe a pled, such as:

— as es ment of the s ructural int egrity of the o je t un e spe if ied se vic lo ding con itions,

pos ibly inclu ing p s ulat ed or k own mat erial fault ;

— o timization of ne es ary p s weld tr atment proc s es for the r lef of welding dist ortionsan / r

r sid al s r s es;

— o timization of welding proc d r s;

— minimization of welding dist ortion an s r s es

4.4 Physical model

Depen ing on the o je tives defined in 4.3, this it em conc rns the compiation of the r spe tive

a pro riat e physical efe t , bou dary con itions an ado t ed simpl fications and as umptions t o be

simulat ed Depen ing on the desir d model complexity, the folowing ex emplary phy sical efe t an

influencing v ria les can be r lev nt :

— heat transp rt via heat cond ction in the sol d;

— conve tion an radiation at the surfac ;

— s r s ve sus s rain;

— mat erials chang es such as mic os ructur trans ormations;

— dis olution or pr cipitation;

— me hanical beha iour such as elas icity;

— ins antaneousor time depen ant-plas icity;

— s rain hardening an r co e y efe t ;

— the mal ex ansion;

— trans ormation in uc d plas icity

These fact ors can be desc ibed eithe b t ext, gra hs, ta les, or formulae The r al b u dary con itions,

mos espe ial y initial t empe atur in the sold, ro m t empe atur , and clamping con itions shal be

desc ibed purp sefuly

The simpl f ications that ha e turned out t o be ne es ary w hen defining the simulations g oals an that

wi be ado t ed in pe forming the simulation shal be desc ibed The subseq ent as umptions shal be

jus if ied b ve if ication an v ldation proc d r s detaied in Clause 6

4.5 Mathematical model and solution method

Based on the fact ors compied in 4.4, a cor esp n ingly suit ed mathematical model shal he e be

def ined To do this, the u de lying es ential dife ential eq ations shal be given or r fe r d t o This

def inition conc rn the g eometrical model (2D, 3D ), sup lement ed b the mathematical desc iption of

the heat our e as wel as of the initial an b un ary con itions In case of g ene al purp se comme cial

me hanical analy sis sof war , the sele t ed o tions of the mathematical solution should be summariz d

Although the ty ical envisag ed solution method is f init e element method (FEM), the solution method

should alway s be s at ed, e.g analytical method, dife ent or complementary n me ical method, or

st ochas ical a pro ch

4.6 Implementation

The desc iption of the implementation comprises spe if ic detais r lating t o the simulation o je t

ac ording t o 4.2 an conc rning the sp tial disc etization, e.g

— FE-meshing inclu ing the spe if ication of the element ty es;

— t emp ral disc etization;

— mat erial charact eris ics;

— initial an b u dary con itions

The r sult of the implementation is the simulation model

5 Wor kflow

5.1 General

The n me ical model ng [choic of finit e element (FE), disc etization, solve , et c.] is a p rt of

computational sold me hanics spe ial s ’ s jo an not in the sco e of this Te h ical Spe ification

The r ade is r fe r d t o ASME V&V 

[2]

w hich pro ides a detaied framework for ve ification an

v ldation (or “v ldation an ve ification ”) of g ene al computational sold me hanics and also t o R6 

[3]

an AW S A9.5 

[4]

for a s an ardiz d t ech iq e for CWM

F ol owing desc iption of the workflow, r commen ed methodolo y for ve if ication an v ldation (or

“v ldation an ve if ication” is given in the next cla use

5.2 Simpl fications and as umptions

5.2.1 General

Simplf ications and as umptions ar a p rt of any simulation model, t o v rying degr es This clause is

int en ed t o ad r s key analy sis input ; those that ar eithe fun amental t o the analy sis, or that the

analysis wi l be p rticularly sensitive t o

5.2.2 Mater ial proper ties

A ccuracy of the pr diction b CWM r les in p rt on the ac uracy of the mo hy sical an

the mome hanical pro e ties used b the models Mat erial pro e ties u c rtainty can be gr atly

r d c d b s at e of the art t es ing; howeve , even in this case, pro e ty det ermination is not pos ible

o e the ful t empe atur rang e of the welding pro lem The efor , as umptions ar inhe ent t o

sele tion of mat erial pro e ties, an shal be thoroughly document ed The ty ical wa of ad r s ing

this unc rtainty is through a sensitivity analy sis t o any pro e ties w hich ar es imat ed or t o any

pro e ties with significant u c rtainty

NOTE Use of a cutof temperature is a common ap ro ch to signif icantly red ce the impact of high

t emperature property u certainty

5.2.3 Mo el s ale and sc ope

One of the primary choic s t o be made for a CWM model is the model scale an sco e The ex ct

desc iption is in the simulation o je t, as def ined in 4.2 If the ex ct desc iption is not implement ed

in the simulation model, then an as umption or simplf ication has be n a pl ed t o the pro lem The

mos common simpl f ication with r spe t t o scale and sco e in the cont ext of CWM is r plac ment of

a 3D model with a 2D ideal zation 3D model ng an analy sis is the mos rig orous a pro ch for CWM;

this is be a use the welding proc s is in e ently 3D an int ensely local for al but the fast es welding

spe ds or thin es se tions Howeve , as long as the simpl f ications used in a given CWM analy ses

ar u de st ood, the degr e of simplfication ma be pe fe tly ac epta le for the spe if ic pro lem

being s u ied In fact, 2D analysis can alow ra id ac es t o oft en q altatively meaningful r sult

2D models ar also useful for hea y se tion multip s welds t o q altatively inves ig t e the imp ct of

weld seq enc chang es and major g eometric chang es Howeve , the spe if ic q al ty of the solution an

ma nitu e of the a pro imation ar s rongly a function of p rt siz , thick es , an welding input A

brief discus ion folow s for the common analysis as umptions The choic of 2D (a isymmetric, plane

s rain, plane s r s ), 3D (brick, sold), or shel model is det ermined b the simulation o je tives an the

charact eris ics of the analy ses

5.2.4 A nal ysis c ouplng

CWM oft en uses a seq ential y-coupled a pro ch, w he e the me hanical analy sis folow s the the mal

analysis The seq ential y-coupled a pro ch is usualy v l d be a use the couplng of the mal,

metalurgical, an me hanical efe t ar mos ly one-wa in fusion welding F or ins anc , the

me hanical s r s and deformation, such as t empe atur rise b plas ic work, ar ex e t ed t o ha e

ve y l t le influenc on the t empe atur dis ribution; nor do they afe t mos phase trans ormations

The seq entialy-coupled a pro ch is much les deman ing computational y than the fuly-coupled

a pro ch

In a fuly-coupled a pro ch, the g ove ning eq ations for heat trans e and those for me hanical s r s

an displac ment ar solved simultaneously Though it is fairly rar , the e ar cases w he e the ful

y-coupled a pro ch is r q ir d for ac urat e simulation r sult The mos nota le ar w hen contact

con itions ma chang e an subs antial y impact heat trans e , or w hen the comp nent t o be welded

ar not rigidly r s rained an g ene at ed larg e dist ortions at the weld location alt er the f it-up con itions

5.3 Proc es des ription and parameter

The proc s desc iption is man at ory t o achieve a n me ical simulation of welding The minimal

information t o g the ar the folowing:

— definition of the welding proc s ;

— a e ag e ene g pe unit length;

— welding spe d;

— welding p th;

— deposition rat e

5.4 Structure and weld g eometr ies

The dimensions of the comp nent shal be given in orde t o draw up it FE-mesh The clamping devic ,

if any, has t o be desc ibed in the same manne

5.5 Materials

5.5.1 General

The b se mat erials, chemical composition shal be given as wel as the as r c ived mat erial condition

The f ile mat erial, if any, has t o be desc ibed in the same man e

5.5.2 Ther mo-physical mater ial pr operties

Computations r q ir t empe atur -depen ent the mo-phy sical pro e ty data within the t empe atur

rang e that oc ur in the mat erial d ring the welding o e ation As only sold s at e computations ar

conside ed, the conve tion in the molt en zone could be modeled b artif icialy inc ease the the mal

con uctivity a o e the fusion t empe atur

5.5.3 Ther mo-mechanical material proper ties

Computations r q ir t empe atur -depen ent the mo-me hanical pro e ties data within the

t empe atur rang e that oc ur in the mat erial d ring the welding o e ation

The mat erials t es ing for me hanical beha iour’ s law identif ication has t o be done as close as pos ible

t o the welding con itions ( i.e high heating an co lng rat e, ac ou ting for phase trans ormations,

un e t ensie, an compr s ive cycles) conside ing cyclc hardening at r lev nt s rain rat e levels

5.6 Loads and boundary c onditions

5.6.1 General

The heat input can be r pr sent ed b a v lumetric or surfac heat sour e Near ly al kin of welding

proc s es can be sim ulat ed using one (or mor ) of those ene g dis ribution sha es or a combination of

them The sha e of the heat sour e an the input ene g can be fitt ed to ex e imental data such as the

the mocouple t empe atur measur ment or the dimensions of the weld p ol an the heat afe t ed zone

5.6.2 Ther mal

The heat trans e analy sis r s s up n the solution of the clas ical heat con uction eq ation with

a pro riat e b u dary con itions The pr cise desc iption of thephenomena inv lved in the heat input

such as ar ar not taken int o ac ou t in the model as wel as the analy sis of fluid dynamics in the weld

p ol R eg rding the the mo-me hanical computation, the fluid flow efe t, w hich leads t o homog eniz