Development of Residual Stress Model for Welded Box Sections Using Probabilistic Simulation Techniques

Abstract Manufacturing processes play a crucial role in inducing imperfections such as residual stresses and distortions in workpieces. This paper investigates weldinginduced residual stresses in box sections composed of both normal strength steel (NSS) and high strength steel (HSS) plates. Advanced manufacturing simulations are performed using deterministic uncoupled transient thermomechanical analysis with a double ellipsoidal heat source model to determine residual stress distributions in weldments applying different steel grades, geometrical dimensions, and welding parameters (e.g., heat input, welding speed, etc.). In addition, the methodology of probabilistic welding simulation is demonstrated. Longitudinal residual stresses in the probabilistic simulation are identified through Monte Carlo simulations using Latin hypercube sampling. The study contributes to the development of a comprehensive residual stress model that directly incorporates welding and fabrication characteristics (i.e., considering manufacturing technology specialties).