Overview

ABOUT THE COURSE:In manufacturing industry over 30% production costs is spent on welding. Knowledge of welding technology, welding deigns, thermos-mechanical and fatigue analyses of welded structures are highly essential in most of the manufacturingindustries. In this present course the primary focus is on basic fundamental of thermos-mechanical and fatigue analysis of welded structure and its importance in industries. This course will also cover different types of thermo-mechanical and fatigue life predictionrelated problem. This course will also include the basics of fusion welding metallurgy. Further this course will also highlight the fundamental of different types of numerical methods used in welding analysis, basics of FE transient elastoplastic thermos-mechanical analysis and detail steps involved in finite element (FE) simulation of weld induced thermal history, residual stresses and distortion using commercially available FE software package ANSYS.INTENDED AUDIENCE: Students/ Researchers/ technical persons form industryPREREQUISITES: BE/B-Tech in Mechanical/Production/ Manufacturing sciences/Power plant engineering/ naval architecture/ ocean engineering.INDUSTRY SUPPORT:Any type of manufacturing industry i.e. automobile,shipbuilding, aeronautical, railway industries etc.

Syllabus

Week 1: Analysis of heat flow in welding: Basics of 3D transientheat transfer analysis, Heat flow in fusion welding, Heat transfer analysis of solid state welding, Effect of operating parameters, Different heat source models for fusion welding, Calculation of peak temperature, and Cooling rate of welds.Week 2:Effect of welding thermal history on welded structure:Effect of welding thermal history and other operating variables on residual stresses and distortions, Thermal effects of welding on parent metal and its mechanical properties, Calculation of welding shrinkage, Heat treatment of welded structure, weldability of structural steels, Thermo-mechanical and overstressing techniques, Hydrogen embrittlement, Hot and cold cracking.Week 3:Basics of welding design: Principle of sound welding design, Joint design, Allowable Strength of welds, Engineering design versus Welding design, Fundamental of fracture mechanics for welding, Theories of failures.Week 4:Design of welded joint for torsional moment and fluctuating loading: Analysis of welded joint subjected to torsional moment, Analysis of welded joint subjected to combined stresses and fluctuating loading, Examples on combined loading.Week 5:The methods of structural fatigue: Fatigue-Analysis Methods, Fatigue Design Methods, Fatigue-life Estimation Methods, Fatigue and creep properties of welded joints, Methods for improving the fatigue strength.Week 6:The methods of structural fatigue: Fatigue-Analysis Methods, Fatigue Design Methods, Fatigue-life Estimation Methods, Fatigue and creep properties of welded joints, Methods for improving the fatigue strength.Week 7:Design & analysis for fatigue loading: Basics of fatigue analysis, mechanism of fatigue fracture, design of welde joints for fatigue loading, infinite and finite life fatigue problems, Rain flow counting method, Examples of Rain flow counting.Week 8:Design & analysis for fatigue loading: Cumulative fatigue life, Miner’s rule for Cumulative fatigue life, Examples of Miner’s rule, Modified Goodman’s diagram and Problems on Modified Goodman’s diagram.Week 9:Design & analysis for fatigue loading: different methods for evaluation of fatigue life of homogeneous welds, crack propagation approach using linear elastic fracture mechanics, Concept of Paris law, Examples of fatigue analysis by Paris law.Week 10:Design & analysis for fatigue loading: Global and local fatigue analysis for welded fatigue analysis i.e. nominal stress method, hot spot stress method, effective notch stress method, Problems on above methods.Week 11:Finite Element (FE) fundamentals required in welding analysis: Concept of different types of numerical methods used in welding analysis, Governing equations and its FE derivation, Basics of FE transient elastoplastic thermos-mechanical analysis.Week 12:Welding Simulation using FE Software ANSYS: FE transient thermal analysis of weld induced thermal history, residual stresses and distortion, basics of fatigue life prediction by FE simulation.