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<p>Fusion welding has long been the primary assembly method in the shipbuilding industry due to its high productivity and operational flexibility. However, a significant drawback is the welding-induced residual stress and distortion, particularly in thin-plate grillage structures. A finite element model based on the Inherent Strain Method (FE-ISM) has been the leading approach for simulating the assembly process of large structures on an industrial scale. In this paper (part 1), a new weld interface model based on a 1D connector element was incorporated with FE-ISM to assess how effectively the simultaneous double-line welding technique can minimize out-of-plane distortion in the skin plate. Inherent strain theory was implemented using the Equivalent Thermal Strain Method (ETSM) using a two-layered laminated composite shell element. Sixteen different welding sequences were designed to investigate the impact of prioritizing the assembly order of either the peripheral or central stiffeners to the skin plate. Simulations indicated that it is advisable to first assemble the frame grid and then attach it to the skin plate. Furthermore, to achieve the least amount of deflection, the peripheral stiffeners should initially be welded to the skin plate to heighten its intermediate structural stiffness, followed by the welding of the central stiffeners. In the accompanying paper (Part 2), the flame-straightening process of the grillage structure assembled using the proposed optimal welding sequence was simulated, using an integrated modeling procedure with the restart analysis technique in ABAQUS/CAE software. Finally, the optimal assembly process was validated through experimental measurements to assess the reliability of simulations.</p>

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Distortion analysis and optimization of grillage structure assembly process by finite element inherent strain method (FE-ISM)-part 1: connector element as a new weld interface model

  • 期刊论文

  • 发表日期：

    2026年2月4日

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  • Behrouz Asadzadeh Totonchi,
  • Koosha Aghazadeh,
  • Behzad Zakeri,
  • Reza Attarnejad

摘要

Fusion welding has long been the primary assembly method in the shipbuilding industry due to its high productivity and operational flexibility. However, a significant drawback is the welding-induced residual stress and distortion, particularly in thin-plate grillage structures. A finite element model based on the Inherent Strain Method (FE-ISM) has been the leading approach for simulating the assembly process of large structures on an industrial scale. In this paper (part 1), a new weld interface model based on a 1D connector element was incorporated with FE-ISM to assess how effectively the simultaneous double-line welding technique can minimize out-of-plane distortion in the skin plate. Inherent strain theory was implemented using the Equivalent Thermal Strain Method (ETSM) using a two-layered laminated composite shell element. Sixteen different welding sequences were designed to investigate the impact of prioritizing the assembly order of either the peripheral or central stiffeners to the skin plate. Simulations indicated that it is advisable to first assemble the frame grid and then attach it to the skin plate. Furthermore, to achieve the least amount of deflection, the peripheral stiffeners should initially be welded to the skin plate to heighten its intermediate structural stiffness, followed by the welding of the central stiffeners. In the accompanying paper (Part 2), the flame-straightening process of the grillage structure assembled using the proposed optimal welding sequence was simulated, using an integrated modeling procedure with the restart analysis technique in ABAQUS/CAE software. Finally, the optimal assembly process was validated through experimental measurements to assess the reliability of simulations.