Optimizing the butt-weld process of pipes based on the inherent strain approach

IF 3 2区工程技术 Q2 ENGINEERING, MECHANICAL

International Journal of Pressure Vessels and Piping Pub Date : 2025-01-17 DOI:10.1016/j.ijpvp.2025.105439

Mohammad Jafari Najafi, Amir Khosravifard, Ali Nayebi

{"title":"Optimizing the butt-weld process of pipes based on the inherent strain approach","authors":"Mohammad Jafari Najafi, Amir Khosravifard, Ali Nayebi","doi":"10.1016/j.ijpvp.2025.105439","DOIUrl":null,"url":null,"abstract":"<div><div>Welded parts often suffer from distortion and residual stresses, leading to assembly inaccuracies and increased costs. To enhance the quality of welded structures, it is essential to predict and mitigate these issues. Traditionally, time-consuming thermo-elastoplastic (TEP) analyses are used to estimate welding stresses and distortions. In the present study, the theory of inherent strain and the elastic finite element method have been employed for accurate and rapid prediction of distortion and residual stresses in butt-welded pipes. Furthermore, to improve the overall weld quality, the genetic algorithm is used to optimize the main arc welding parameters such as welding power and the ratio of input heat to pipe thickness and the number of intermittent welding sections. The accuracy of the analyses is validated by comparing the simulation results with the FEM and experimental results of [1]. The optimization of the welding process was able to reduce the residual stress and deformation by 5 % and 9 %, respectively. The inherent strain method has been shown to reduce the computational cost of the analyses by more than 95 %, compared to the conventional TEP analysis, while preserving an acceptable accuracy in terms of the predicted residual stresses and deformations.</div></div>","PeriodicalId":54946,"journal":{"name":"International Journal of Pressure Vessels and Piping","volume":"214 ","pages":"Article 105439"},"PeriodicalIF":3.0000,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"International Journal of Pressure Vessels and Piping","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S0308016125000092","RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"ENGINEERING, MECHANICAL","Score":null,"Total":0}

引用次数: 0

Abstract

Welded parts often suffer from distortion and residual stresses, leading to assembly inaccuracies and increased costs. To enhance the quality of welded structures, it is essential to predict and mitigate these issues. Traditionally, time-consuming thermo-elastoplastic (TEP) analyses are used to estimate welding stresses and distortions. In the present study, the theory of inherent strain and the elastic finite element method have been employed for accurate and rapid prediction of distortion and residual stresses in butt-welded pipes. Furthermore, to improve the overall weld quality, the genetic algorithm is used to optimize the main arc welding parameters such as welding power and the ratio of input heat to pipe thickness and the number of intermittent welding sections. The accuracy of the analyses is validated by comparing the simulation results with the FEM and experimental results of [1]. The optimization of the welding process was able to reduce the residual stress and deformation by 5 % and 9 %, respectively. The inherent strain method has been shown to reduce the computational cost of the analyses by more than 95 %, compared to the conventional TEP analysis, while preserving an acceptable accuracy in terms of the predicted residual stresses and deformations.

查看原文本刊更多论文

求助全文

约1分钟内获得全文求助全文

来源期刊

International Journal of Pressure Vessels and Piping 工程技术-工程：机械

CiteScore

5.30

自引率

13.30%

发文量

208

审稿时长

17 months

期刊介绍： Pressure vessel engineering technology is of importance in many branches of industry. This journal publishes the latest research results and related information on all its associated aspects, with particular emphasis on the structural integrity assessment, maintenance and life extension of pressurised process engineering plants. The anticipated coverage of the International Journal of Pressure Vessels and Piping ranges from simple mass-produced pressure vessels to large custom-built vessels and tanks. Pressure vessels technology is a developing field, and contributions on the following topics will therefore be welcome: • Pressure vessel engineering • Structural integrity assessment • Design methods • Codes and standards • Fabrication and welding • Materials properties requirements • Inspection and quality management • Maintenance and life extension • Ageing and environmental effects • Life management Of particular importance are papers covering aspects of significant practical application which could lead to major improvements in economy, reliability and useful life. While most accepted papers represent the results of original applied research, critical reviews of topical interest by world-leading experts will also appear from time to time. International Journal of Pressure Vessels and Piping is indispensable reading for engineering professionals involved in the energy, petrochemicals, process plant, transport, aerospace and related industries; for manufacturers of pressure vessels and ancillary equipment; and for academics pursuing research in these areas.