Effect of Welding Speed on Residual Stress and Distortion of AISI 1045 Plate Using the Finite Element Method (FEM)

Abstract

Welding is one of the metals joining methods to assembly parts which are used in manufacturing, automotive, and aerospace industries. The welding process merely simulated in modelling using finite element method (FEM). Simulation is used to determine how the effect of welding speed on the distribution of temperature, residual stress, and deformation in the V-Butt Joint welding model. The material used in this welding simulation is AISI 1045 plate with a thickness of 8 mm. Variable speed of welding performed in 30 cm/minute, 40 cm/minute and 50 cm/minute. As the result, the residual stress and distortion will be compared in order to find the best welding speed which produces the smallest residual stress and distortion value. Welding simulation based on SMAW with 6.3 mm of E7016 electrode, current of 150 A, voltage of 26 V, and single-pass welding. The finite element method using the ANSYS 2020 R2 software for simulation. Welding simulation uses transient thermal and moving heat flux features, while residual stresses and distortion use static structural features. From this research, the maximum temperature distribution after welding at welding speeds of 30 cm/minute, 40 cm/minute and 50 cm/minute were 295.22 ℃, 240.59 ℃ and 205.94 ℃, respectively. In this study, the welding speed of 30cm/minute has the highest values of residual stress and distortion, which is about 0.00000036965 MPa and 0.090894 mm. Besides, for welding speed of 40 cm/minute and 50 cm/minute, the total residual stress and total distortion value are 0.00000027744 MPa; 0.067248 mm and 0.00000022218 MPa; 0.053419 mm, respectively.