Prediction of welding distortion in butt joint of thin plates

This paper investigates distortions and residual stresses induced in butt joint of thin plates using Metal Inert Gas welding. A moving distributed heat source model based on Goldak's double-ellipsoid heat flux distribution is implemented in Finite Element (FE) simulation of the welding process. Thermo-elastic-plastic FE methods are applied to modelling thermal and mechanical behaviour of the welded plate during the welding process. Prediction of temperature variations, fusion zone and heat affected zone as well as longitudinal and transverse shrinkage, angular distortion, and residual stress is obtained. FE analysis results of welding distortions are compared with existing experimental and empirical predictions. The welding speed and plate thickness are shown to have considerable effects on welding distortions and residual stresses. © 2009 Elsevier Ltd. All rights reserved.

The vibrational spectra of rectangular plates

The wire drive pulse-echo system has been extensively used to excite and measure modes of vibration of thin rectangular plates. The frequency spectra of different modes have been investigated as a function of the material elastic moduli and the plate geometry. Most of the work was carried out on isotropic materials. For square plates a wide selection of materials were used. These were made isotropic in their in-plane dimensions where the displacements are taking place. The range of rnaterials enabled the dependence on Poisson's ratio to be investigated. A method of determining the value of Poisson's ratio resulted from this investigation. Certain modes are controlled principally by the shear modulus. Of these the fundamental has two nodal lines across the plate surface. One of them, which has nodes at the corners, (the Lame mode) is uniquely a pure shear mode where the diagonal is a full wave length. One controlled by the Young's modulus has been found. The precise harmonic relationship of the Lame mode series in square and rectangular plates was established. Use of the Rayleigh-Lamb equation has extended the theoretical support. The low order modes were followed over a wide range of sides ratios. Two fundamental types of modes have been recognised; These are the longitudinal modes where the frequency is controlled by the length of the plate only and the 2~f product has an asymptotic value approaching the rod velocity. The other type is the in-plane flexural modes (in effect a flexurally vibrating bar where the -2/w is the geometrical parameter). Where possible the experimental work was related to theory. Other modes controlled by the width dimension of the plate were followed. Anisotropic materials having rolled sheet elastic symmetry were investigated in terms of the appropriate theory. The work has been extended to examine materials from welds in steel plates.

The mechanics of continuous roller bending of plates

This research initiates a study of the mechanics of four roll plate bending and provides a methodology to investigate the process experimentally. To carry out the research a suitable model bender was designed and constructed. The model bender was comprehensively instrumented with ten load cells, three torquemeters and a tachometer. A rudimentary analysis of the four roll pre-bending mode considered the three critical bending operations. The analysis also gave an assessment of the model bender capacity for the design stage. The analysis indicated that an increase in the coefficient of friction in the contact region of the pinch rolls and the plate would reduce the pinch resultant force required to end a plate to a particular bend radius. The mechanisms involved in the four roll plate bending process were investigated and a mathematical model evolved to determine the mechanics of four roll thin plate bending. A theoretical and experimental investigation was conducted for the bending of HP30 aluminium plates in both single and multipass bending modes. The study indicated that the multipass plate bending mechanics of the process varied according to the number of bending passes executed and the step decrement of the anticipated finished bend radius in any two successive passes (i.e. the bending route). Experimental results for single pass bending indicated that the rollers normally exert a higher bending load for the steady-continous bending with the pre-inactive side roll oper?tive. For the pre-bending mode and the steady-continous bending mode with the pre-active side roll operative, the former exerted the higher loads. The single pass results also indicated that the force on the side roll, the torque and power steadily increased as the anticipated bend radius decreased. Theoretical predictions for the plate internal resistance to accomplish finished bend radii of between 2500mm and 500mm for multipass bending HP30 aluminium plates, suggested that there was a certain bending route which would effectively optimise the bender capacity.