1、BSI Standards Publication PD ISO/TS 18166:2016 Numerical welding simulation Execution and documentationPD ISO/TS 18166:2016 PUBLISHED DOCUMENT National foreword This Published Document is the UK implementation of ISO/TS 18166:2016. The UK participation in its preparation was entrusted to Technical C
2、ommittee WEE/-/1, Briefing committee for welding. A list of organizations represented on this committee can be obtained on request to its secretary. This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. The British
3、 Standards Institution 2016. Published by BSI Standards Limited 2016 ISBN 978 0 580 82902 4 ICS 25.160.01 Compliance with a British Standard cannot confer immunity from legal obligations. This Published Document was published under the authority of the Standards Policy and Strategy Committee on 31 M
4、arch 2016. Amendments issued since publication Date Text affectedPD ISO/TS 18166:2016 ISO 2016 Numerical welding simulation Execution and documentation Simulation numrique de soudage Excution et documentation TECHNICAL SPECIFICATION ISO/TS 18166 Reference number ISO/TS 18166:2016(E) First edition 20
5、16-03-01PD ISO/TS 18166:2016ISO/TS 18166:2016(E)ii ISO 2016 All rights reserved COPYRIGHT PROTECTED DOCUMENT ISO 2016, Published in Switzerland All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized otherwise in any form or by any means, electronic
6、 or mechanical, including photocopying, or posting on the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address below or ISOs member body in the country of the requester. ISO copyright office Ch. de Blandonnet 8 CP 401 CH-1214 Vernier,
7、Geneva, Switzerland Tel. +41 22 749 01 11 Fax +41 22 749 09 47 copyrightiso.org www.iso.orgPD ISO/TS 18166:2016ISO/TS 18166:2016(E)Foreword v 1 Scope . 1 2 Normative references 2 3 T erms and definitions . 2 4 Description of the problem . 3 4.1 General . 3 4.2 Simulation object 4 4.3 Simulation obje
8、ctives 4 4.4 Physical model . 4 4.5 Mathematical model and solution method . 5 4.6 Implementation 5 5 W or kflo w 5 5.1 General . 5 5.2 Simplifications and assumptions 6 5.2.1 General 6 5.2.2 Material properties 6 5.2.3 Model scale and scope . 6 5.2.4 Analysis coupling . 6 5.3 Process description an
9、d parameters . 7 5.4 Structure and weld geometries 7 5.5 Materials . 7 5.5.1 General 7 5.5.2 Thermo-physical material properties . 7 5.5.3 Thermo-mechanical material properties . 7 5.6 Loads and boundary conditions. 7 5.6.1 General 7 5.6.2 Thermal 7 5.6.3 Mechanical 8 5.7 Results review . 8 5.8 Repo
10、rting . 8 6 V alidation and v erification 8 6.1 General . 8 6.2 Verification of the simulation model 8 6.3 Calibration of the model parameters . 8 6.4 Plausibility check of the simulation results . 9 6.5 Validation of the simulation results 9 6.5.1 General 9 6.5.2 Validation experiment guidelines .
11、9 7 Reporting/display of results 9 7.1 General . 9 7.2 Simulation object 9 7.3 Material properties and input data 10 7.4 Process parameter 10 7.5 Meshing 10 7.6 Numerical model parameters .10 7.7 Analysis of results 10 Annex A (informative) Documentation template .11 Annex B (informative) Modelling
12、of heat transfer during welding 12 Annex C (informative) Validation experiment guidelines .14 Annex D (informative) Modelling of residual stresses 16 ISO 2016 All rights reserved iii Contents PagePD ISO/TS 18166:2016ISO/TS 18166:2016(E)Annex E (informative) Distortion prediction 17 Bibliography .19
13、iv ISO 2016 All rights reservedPD ISO/TS 18166:2016ISO/TS 18166:2016(E) Foreword ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standards is normally carried out through ISO tech
14、nical committees. Each member body interested in a subject for which a technical committee has been established has the right to be represented on that committee. International organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely
15、 with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization. The procedures used to develop this document and those intended for its further maintenance are described in the ISO/IEC Directives, Part 1. In particular the different approval criteria nee
16、ded for the different types of ISO documents should be noted. This document was drafted in accordance with the editorial rules of the ISO/IEC Directives, Part 2 (see www.iso.org/directives). Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
17、 rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of any patent rights identified during the development of the document will be in the Introduction and/or on the ISO list of patent declarations received (see www.iso.org/patents). Any trade name used i
18、n this document is information given for the convenience of users and does not constitute an endorsement. For an explanation on the meaning of ISO specific terms and expressions related to conformity assessment, as well as information about ISOs adherence to the WTO principles in the Technical Barri
19、ers to Trade (TBT) see the following URL: Foreword - Supplementary information The committee responsible for this document is ISO/TC 44, Welding and allied processes. Requests for official interpretations of any aspect of this Technical Specification should be directed to the Secretariat of ISO/TC 4
20、4 via your national standards body. A complete listing of these bodies can be found at www.iso.org. ISO 2016 All rights reserved vPD ISO/TS 18166:2016PD ISO/TS 18166:2016Numerical welding simulation Execution and documentation 1 Scope This Technical Specification provides a workflow for the executio
21、n, validation, verification and documentation of a numerical welding simulation within the field of computational welding mechanics (CWM). As such, it primarily addresses thermal and mechanical finite element analysis (FEA) of the fusion welding (see ISO/TR 25901:2007, 2.165) of metal parts and fabr
22、ications. CWM is a broad and growing area of engineering analysis. This Technical Specification covers the following aspects and results of CWM, excluding simulation of the process itself: heat flow during the analysis of one or more passes; thermal expansion as a result of the heat flow; thermal st
23、resses; development of inelastic strains; effect of temperature on material properties; predictions of residual stress distributions; predictions of welding distortion. This Technical Specification refers to the following physical effects, but these are not covered in depth: physics of the heat sour
24、ce (e.g. laser or welding arc); physics of the melt pool (and key hole for power beam welds); creation and retention of non-equilibrium solid phases; solution and precipitation of second phase particles; effect of microstructure on material properties. The guidance given by this Technical Specificat
25、ion has not been prepared for use in a specific industry. CWM can be beneficial in design and assessment of a wide range of components. It is anticipated that it will enable industrial bodies or companies to define required levels of CWM for specific applications. This Technical Specification is ind
26、ependent of the software and implementation, and therefore is not restricted to FEA, or to any particular industry. It provides a consistent framework for-primary aspects of the commonly adopted methods and goals of CWM (including validation and verification to allow an objective judgment of simulat
27、ion results). Through presentation and description of the minimal required aspects of a complete numerical welding simulation, an introduction to computational welding mechanics (CWM) is also provided. (Examples are provided to illustrate the application of this Technical Specification, which can fu
28、rther aid those interested in developing CWM competency). Clause 4 of this Technical Specification provides more detailed information relating to the generally valid simulation structure and to the corresponding application. Clause 5 refers to corresponding TECHNICAL SPECIFICATION ISO/TS 18166:2016(
29、E) ISO 2016 All rights reserved 1PD ISO/TS 18166:2016ISO/TS 18166:2016(E) parts of this Technical Specification in which the structure for the respective application cases is put in concrete terms and examples are given. Annex A presents a documentation template to promote the consistency of the rep
30、orted simulation results. 2 Normative references The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced doc
31、ument (including any amendments) applies. ISO/TR 25901, Welding and related processes Vocabulary 3 T erms a nd definiti ons For the purposes of this document, the terms and definitions given in ISO/TR 25901 and the following apply. 3.1 boundary conditions conditions imposed at the spatial boundary o
32、f a computational model that describe the interaction between the modelled and unmodelled domains Note 1 to entry: Complete boundary conditions provide a unique solution to the specific mathematical problem being solved. 3.2 geometric model description of all geometries analysed within a simulation
33、including the dimensionality of the simulation object 3.3 mathematical model model comprising the underlying essential mathematical equations including the appropriate initial and boundary conditions 3.4 numerical simulation simulation performed by adopting approximate mathematical methods generally
34、 performed on a computer 3.5 physical model full array of the physical process to be simulated and boundary and initial conditions relevant to the simulation object as well as adopted simplifications and assumptions 3.6 plausibility check check of the obtained calculation results in respect of their
35、 conformity with basic physical principles 3.7 simulation model combination of the physical, geometrical and mathematical models and the solution method 3.8 spatial discretization distribution and type of the geometric units for subdividing the geometric model 3.9 temporal discretization step size a
36、nd number of time units for subdividing the duration being modeled2 ISO 2016 All rights reservedPD ISO/TS 18166:2016ISO/TS 18166:2016(E) 3.10 validation process of determining the degree to which a model is an accurate representation of the physical problem from the perspective of the intended uses
37、of the model 3.11 validation experiment experiment designed specifically for validating the simulation results taking account of all relevant data and their uncertainty 3.12 ve r i f ic at ion demonstration of the correctness of the simulation model 3.13 calibration process of adjusting modelling pa
38、rameter values in the simulation model for the purpose of improving agreement with reliable experimental data 3.14 model mathematical representation of a physical system or process 3.15 f i n it e el em en t a n a l y s i s FEA numerical method for solving partial differential equations that describ
39、es the response of a system to loading 3.16 h e a t f l u x rate at which thermal energy is transferred through a unit area of surface 3.17 power density amount of thermal power absorbed or generated per unit volume 3.18 prediction estimation of the response of a physical system using a mathematical
40、 model 3.19 computational welding mechanics CWM subset of numerical simulation and analysis of welding 4 Description of the problem 4.1 General Computational welding mechanics is a subset of numerical simulation and analysis of welding that is primarily accomplished through use of the finite element
41、 method. Nonlinear thermal and mechanical analyses are performed, which can be sequentially or fully coupled, where the welding power is applied to the computational model in some way, and the resulting transient temperature (and possibly microstructure) fields are then combined with mechanical mate
42、rial properties/models and boundary conditions to predict the stress and strain in the model and its distortion. This description is not intended to be all inclusive or restrictive, but is provided to establish the typical expected use to which this Technical Specification might apply. ISO 2016 All
43、rights reserved 3PD ISO/TS 18166:2016ISO/TS 18166:2016(E) This Technical Specification addresses the general CWM problem, which can be defined as a three- dimensional solid element model employing a travelling power density heat source with simultaneous calculation of temperature, microstructure and
44、 displacement, utilizing elasto-visco-plastic constitutive models based on material properties ranging from room temperature to beyond the melting temperature. This does not preclude use of simplified methods, but rather provides a simulation method benchmark from which simplifications can be judged
45、. The need for simplifications are primarily driven by computational limitations (size and speed), and apply to many industry problems, such as heavy section welds in the pressure vessel or shipbuilding industries. As any simplification of the mathematical model that represents the physical system m
46、ay increase uncertainty in the simulation results, this shall be counterbalanced with more effort in verification and validation of the model. Note that all computational models require verification and validation, and this subject is addressed in greater detail in Clause 6. The preceding discussion
47、 is formalized and expanded upon in the remaining subclauses. 4.2 Simulation object The first item comprises the exact description of the component or overall structure, respectively, to be investigated (e.g. geometry, service conditions), of the employed base and filler materials, of the welding pr
48、ocedure and parameters, of the applied welding sequence as well as of the restraint conditions. Optionally, a complementary graphical representation or photograph may be attached. 4.3 Simulation objectives This item concerns the definition of the desired simulation results which ensue from the real
49、task at hand. This is particularly important since many realistic problems still require simplification in order to be analysed with reasonable effort. Examples include the calculation of welding residual stresses and/or distortions, the assessment of the heat affected zone and its characteristics or the welding procedure net heat input. In addition, the ultimate aim should be stated to which the desired simulation results are intended to be further applied, such as: assessment of the structural integrity of the object
