Virtual manufacturing and experimental validation of distortion in laser welding of butt joint

Abstract

This research explores the distortion behavior of welded butt joints using virtual manufacturing (VM) analysis. The main aim is to compare and validate the simulation outcomes generated through APDL (Ansys Parametric Design Language) with experimental results. A nonlinear, three-dimensional finite element method (FEM)-based VM framework is utilized for the simulations. To enhance modeling efficiency, the complexity of the weld geometry and the impact of transient temperature distribution are deliberately reduced. The heat input for the butt joint is simulated using Goldak’s double ellipsoid model. Furthermore, a flow curve corresponding to S235 low-carbon steel is applied, incorporating a constant strain rate of 0.001 s⁻¹, modeled using a nonlinear isotropic plasticity approach and the von Mises yield criterion. The results demonstrate that simplifying the weld geometry and material definitions substantially reduces the pre-processing time without significantly compromising the accuracy of distortion predictions. Both simulation methods exhibited high precision in forecasting angular distortion, with an average deviation of approximately 20%, indicating no significant practical discrepancy. Therefore, the simplified modeling strategy, omitting detailed heat source modeling, temperature calibration, and complex material characterization, is recommended for scenarios where time constraints exist and a moderate level of accuracy is sufficient.

Keyword: Virtual manufacturing, APDL, Experimental validation, Goldak’s double ellipsoid method, Angular distortion.