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    CategoryB Lenzo Orr 1stPLACE

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    Jhoncastillo
    Repair

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    CategoryB Lenzo Orr 1stPLACE

    Uploaded by

    Jhoncastillo
    27 views1 page
    Repair

    Original Title

    CategoryB-Lenzo-Orr-1stPLACE

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    27 views1 page

    CategoryB Lenzo Orr 1stPLACE

    Uploaded by

    Jhoncastillo
    Repair

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 1

    Distortion Modeling of Wheel Loader

    Articulation Joint
    Authors: Jansen Lenzo and Michael Orr
    Advisor: Dr. Wei Zhang, The Ohio State University
    Sponsor: Bill DePorter, Joy Global, Inc.

    Background
    Welding is extensively used in assembling
    large steel structures in earth-moving vehicles such
    as wheel loaders. These joints undergo cyclic
    loading from lifting and lowering the large earth-
    moving buckets with payload capacities from 100
    to 400 short tons.
    During welding, the non-uniform heating and
    cooling thermal cycles cause the parts to distort.
    Such welding-induced distortion can have a
    detrimental effect on the performance of the
    welded structures. In this research, the welding-
    induced distortion in the ball-and-socket joints on a
    wheel loader (shown to the right) is studied.
    Pictures courtesy of Joy Global Inc.

    Motivation Results & Discussion


    Preprocessing with ABAQUS/CAE
    •  Distortion following welding of the articulation joint can result in The complex ball-and-socket assembly was
    costly rework and repair. sectioned into a simpler geometry in order to
    •  Through the use of modeling software programs, the welding- reduce computing time while still validating
    induced distortion can be simulated with known material properties distortion modeling.
    Using ABAQUS, the geometry was
    and welding parameters used during fabrication. partitioned into sub-sections in order to procure
    •  The simulated parts can be examined and aid in reducing welding- higher mesh densities in regions of interest
    induced distortion during the fabrication process. (high heat input areas).

    Post-processing with SYSWELD


    ABAQUS file was imported into
    Objectives & Approach SYSWELD for post-processing.
    Main Objective: To begin the process of developing analytical methods to examine Welding parameters were inputted to
    distortion in heavy-plate weldments. accurately resemble actual
    fabrication. Distributions of
    •  Develop the base computational model to maximum temperature, residual
    represent existing distortion at articulation stress, and distortion were produced
    joints for all four welding sequences.
    •  Demonstrate the qualitative and
    Graphs resembling magnitudes of
    quantitative capabilities of the software
    these outputs are also available. The
    used to develop these welding simulations
    figure to the left shows these visual
    •  Lay groundwork for future modeling of
    distributions and a von mises stress
    articulation joint by modeling a small
    distribution graph for the alternating
    portion of the assembly
    weld sequence. With the correct
    Two-Phase Approach: parameter inputs, this study’s two-
    I.  Background Research step process can simulate distortion in
    II.  Distortion Modeling this assembly. Further work requires
    i. Preprocessing: correlation with physical data.
    ABAQUS
    ii. Processing/Post-processing:
    SYSWELD
    Four different welding
    sequences were simulated to
    Conclusions study the effect it imposes.
    The table to the right shows
    •  This two-step modeling technique is a viable qualitative measure to the descriptions for each
    model the distortion for the ball-and-socket assembly welding sequence. The figure
    below shows the maximum
    •  The ability to visualize the effects of varying welding parameters can distortion distribution for
    aid in controlling distortion each sequence. Similar
    •  Modeling is a time and cost-effective way to obtain quantitative results results were observed in trials
    that correlate with real-world fabrication #1, 2, and 4 with magnitudes
    from 3.7-4.19 mm of
    displacement. Trial #3
    Future Work exhibited maximum
    distortion in another region
    •  Model remainder of part and welding of four corner joints of the part. This variance is
    •  Determine optimal welding sequence to minimize distortion due to different thermal and
    •  Model various clamping and preset conditions stress patterns from tandem
    •  Obtain quantitative correlation with real-world fabrication welding.

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