A streamlined FE method for deformation and residual stress prediction in butt welding using continuous heat input

Finite element (FE) analysis is useful to estimate and predict deformation and residual stress generated by welding. To improve the efficiency of the FE analysis for the welding process, this study proposed an element combination and heat input method for simulating the butt welding process on steel with a V-shaped groove. This method integrated shell and solid elements and input heat energy continuously into the weld metal elements considering the energy distribution. Additionally, a parametric study of the double ellipsoidal model was conducted within the Continuous Distributed (CD) heat input method to identify optimal parameters for accurately simulating the heat source. The simulation results of the models using different heat input methods of deformation and residual stress were in good agreement with the experimental results, and the model using the continuously distributed heat input method saved 54% computational time compared to that by a conventional heat input method without considering the energy distribution. It was indicated that the proposed method for simulating the butt welding process was effective and could significantly reduce computational time.