Weld Design of Vehicle Bodies and Analysis of Welded Butt and T-joints Using Simufact

Nowadays Weld design plays a more important role in the welding process has been used extensively in the fabrication of many structures including vehicle bodies, train, ships, buildings, air planes, bridges, pressure vessels, etc. The major focus in the weld design of vehicle bodies manufacturing industries is design of weld joints with more pay load capacity and possible less weight. It provides many advantages over other joining techniques. To mention only a few, it provides better mechanical properties and good joining efficiency. An important aspect of weld design of vehicle bodies and analysis is the stress distribution and fatigue life of prediction process. Fatigue is one of the most important parameters to consider when weld design of vehicle bodies. However, there are various problems such as residual stresses and shape distortion associated with the construction of welded structures. When a material is being welded, it experiences local heat due to the welding heat source. The temperature field inside the weld meant is not uniform and changes as the welding progresses. The welding heat cycle gives rise to a complex strain field in the weld metal and in the base metal regions near the weld. These strains, along with the plastic upsetting, create the residual stresses that remain after the welding is completed. In addition, shrinkage and distortion are also produced. Residual stresses and distortion are highly undesirable in welding technology. Thermal stresses during welding often cause cracking. Some of the above weld related problems can be solved by adhering to a preset weld design practice and employing appropriate weld process procedure in the welding tasks. In developing country there are limited numbers of vehicles body builders. Those body builders extensively use welding. In those local body builders there is lack of proper weld design practice in the fabrication of vehicle bodies. Moreover, there is no well developed welding process procedure they have adapted. As well as a FEM using simulating manufacturing /simufact / software has been performed in order to achieve a higher understand welding process and mechanical properties.