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<p>To mitigate welding-induced deformation that affects the assembly accuracy of shock absorber oil storage pipes, this study develops a thermomechanical finite element model integrating a calibrated double-ellipsoid heat source and sequential coupling. High-temperature material parameters were obtained using JMatPro, and a user-defined Dflux subroutine was implemented in Abaqus to capture the transient heat input. The analysis focuses on circumferential residual stress nonuniformity and the resulting elliptical port deformation, rather than only residual stresses as in conventional studies. Results show that residual deformation is concentrated at the free end of the pipe. Quantitative comparison with 3D-scanned deformation profiles shows that the calibrated model achieves high predictive fidelity, with port deformation errors ranging from 0.3 to 4.6%, and maximum deformation predictions of 1.05&#xa0;mm versus 1.00&#xa0;mm experimentally, corresponding to an accuracy above 95%. These results highlight the superior capability of the double-ellipsoid formulation in reproducing asymmetric heat flow and deformation characteristics in thin-walled tubular components. The validated framework provides an effective tool for deformation prediction and process optimization in automotive shock absorber welding.</p>

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Thermal-Mechanical Simulation of Welding Deformation in an Automotive Shock Absorber Using a Double-Ellipsoid Heat Source Model

  • 期刊论文

  • 发表日期：

    2026年3月6日

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  • Jun Ke,
  • Zhenjie Zhou,
  • Fang Meng,
  • Dongwei Luo,
  • Wenqi Lu,
  • Jun Pan,
  • Liangcheng Zhang

摘要

To mitigate welding-induced deformation that affects the assembly accuracy of shock absorber oil storage pipes, this study develops a thermomechanical finite element model integrating a calibrated double-ellipsoid heat source and sequential coupling. High-temperature material parameters were obtained using JMatPro, and a user-defined Dflux subroutine was implemented in Abaqus to capture the transient heat input. The analysis focuses on circumferential residual stress nonuniformity and the resulting elliptical port deformation, rather than only residual stresses as in conventional studies. Results show that residual deformation is concentrated at the free end of the pipe. Quantitative comparison with 3D-scanned deformation profiles shows that the calibrated model achieves high predictive fidelity, with port deformation errors ranging from 0.3 to 4.6%, and maximum deformation predictions of 1.05 mm versus 1.00 mm experimentally, corresponding to an accuracy above 95%. These results highlight the superior capability of the double-ellipsoid formulation in reproducing asymmetric heat flow and deformation characteristics in thin-walled tubular components. The validated framework provides an effective tool for deformation prediction and process optimization in automotive shock absorber welding.