Chaining of welding and finish turning simulations for austenitic stainless steel components

Abstract

The chaining of manufacturing processes is a major issue for industrials who want to understand and control the quality of their products in order to ensure their in-service integrity (surface integrity, residual stresses, microstructure, metallurgical changes, distortions,…). Historically, welding and machining are among the most studied processes and dedicated approaches of simulation have been developed to provide reliable and relevant results in an industrial context with safety requirements. As the simulation of these two processes seems to be at an operationnal level, the virtual chaining of both must now be applied with a lifetime prediction prospect. This paper will first present a robust method to simulate multipass welding processes that has been validated through an international round robin. Then the dedicated “hybrid method”, specifically set up to simulate finish turning, will be subsequently applied to the welding simulation so as to reproduce the final state of the pipe manufacturing and its interaction with previous operations. Final residual stress fields will be presented and compared to intermediary results obtained after welding. The influence of each step on the final results will be highlighted regarding surface integrity and finally ongoing validation works and numerical modeling enhancements will be discussed.