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Cumulative Angular Distortion Curve of Multi-Pass Welding at Thick Plate of Offshore Structures
Ha, Yunsok,Choi, Jiwon Korean Society of Ocean Engineers 2015 Journal of advanced research in ocean engineering Vol.1 No.2
In the fabrication of offshore oil and gas facilities, the significance of dimension control is growing continuously. But, it is difficult to determine the deformation of the structure during fabrication by simple lab tests due to the large size and the complicated shape. Strain-boundary method (a kind of shrinkage method) based on the shell element was proposed to predict the welding distortion of a structure effectively. Modeling of weld geometry in shell element is still a difficult task. In this paper, a concept of imaginary temperature pair is introduced to handle the effect of geometric factors such as groove shape, plate thickness and pass number, etc. Single pass imaginary temperature pair formula is derived from the relation between the groove area and the FE mesh size. By considering the contribution of each weld layer to the whole weldment, multi-pass imaginary temperature is also derived. Since the temperature difference represents the distortion increment, cumulative distortion curve can be drawn by integrating the temperature difference. This curve will be a useful solution when engineers meet some problems occurred in the shipyard. A typical example is shown about utilization of this curve. Several verifications are conducted to examine the validity of the proposed methodology. The applicability of the model is also demonstrated by applying it to the fabrication process of the heavy ship block. It is expected that the imaginary temperature model can effectively solve the modeling problem in shell element. It is also expected that the cumulative distortion curve derived from the imaginary temperature can offer useful qualitative information about angular distortion without FE analysis.
Thermal Distortion Analysis by Inconel Over-Lay At Circular Moonpool Structures
Ha, Yunsok Korean Society of Ocean Engineers 2013 International journal of ocean system engineering Vol.3 No.2
This study is mainly interested in roundness of a circular moonpool structure in FPSO. Because this structure needs abrasion-resistance on inner wall, we should do buttering widely and deeply by using Inconel. But a general buttering can cause a severe distortion at structures. If someone can analyze the roundness by thermal distortion under Inconel over-lay, an erection policy can be established. In this study, shrinkage methodology by designed stress-strain curve was used and the result allowed deciding an appropriate block size.
A Study on Remaining Efficiency of Thermal Straightening after Block Lifting
Ha, Yunsok,Yi, Myungsu Korean Society of Ocean Engineers 2015 Journal of advanced research in ocean engineering Vol.1 No.3
Deck plates of ships or offshore structures would make out-of-plane distortion for their thin thickness. These distortions are usually straightened by thermal straightening such as flame heating method. After thermal straightening, the blocks are lifted and moved by cranes to assemble it at dry-dock stage. After this lifting process, out-of-plane deformation again happens frequently. And then, they continuously cause quality and accuracy problems in the final dry-dock process. So, it takes more time for repair and correction working. According to preceding research, the lifting process by cranes would offset the effect on thermal straightening. The target of this study is to develop a methodology analyzing the remaining efficiency of thermal straightening after block lifting. The development was based on the assumption of yield state at straightening region. Therefore the remaining efficiency was obtained by different stiffness slope while lifting & relieving. The efficiency formula was designed using inherent strain, and we made a table of zero-efficiency by cooling speed and class rule's steels. As a result, if the stress orthogonal to straightened line is calculated during lifting analysis by FEA, the efficiency can be obtained linearly to the values in the table. Finally, even optimized carling position can be designed by considering the regional data from series project and welding region on deck.
용접구조물의 변형 최소화를 위한 최적 용접순서의 해석적 방법
하윤석,Ha, Yunsok 대한용접접합학회 2013 대한용접·접합학회지 Vol.31 No.3
Several methodologies analyzing welding distortions of large shell structures like ship blocks have been developed and utilized in shipyards for a long times ago. In general, one of objects of thermal distortion analysis is to find welding sequence making least-deformation without any suppliance, and it can be solved easily and rapidly by EP strain-boundary method. But after assembly construction, there are usually more than 10 weldments in each process, and the number of sequence will follow the Factorial calculation. In this research, a method has been suggested to decide the best welding sequence by minimum analysis. Using this method, welding deformation could be reduced just analyzing some cases as many as the number of weldments. Experiments and Analysis of all cases were also done, and their best results are good agreements with predictation by suggested methodology.
하윤석,이명수,Ha, Yunsok,Yi, Myungsu 대한용접접합학회 2015 대한용접·접합학회지 Vol.33 No.3
A very large shell-structure built in shipyards like ship hulls or offshore structures are joined by welding through full process. As the welding contains a high thermal cycle at a local area, the welded structures should be distorted unavoidably. Because a distorted ship block should be revised to the designed value before the next stage, the ability to predict and to control the weld distortion is an accuracy level of the yard itself. Despite the ship block size, several present thermal distortion methodologies can deal those sizes, but it is a different story to deal full ship size model. Even a fully constructed ship hull not remaining any welding can have an accuracy issue like outfitting installation problems. Any present thermal distortion methodology cannot accept this size for its recommended element size and the number. The ordinary welding breadth at erection stage is about 20~40 mm. It can hardly be a good choice to make finite element model of these sizes considering human effort and computational environment. The finite element model for structure analysis of a ship hull is prepared at front-end engineering design stage which is the first process of the project. The element size of the model is as fine as the longitudinal space, and it is not proper to obtain a weld distortion at the erection stage. In this study, a methodology is suggested that a weldment can be shrunk at original place instead of using structural finite element model. We cut the original shell elements at erection weld-line and put truss elements between the edges of cut elements for weld shrinkage. Additional truss elements are used to facsimile transverse weld shrinkage which cannot be from the weld-line truss element shrink. They attach to weld-line truss element like twigs from barks. The capacity of developed elements is verified through an accuracy check of erection process of a container vessel at the apt. hull. It can be a useful tool for verifying a centering accuracy after renew and for block-separating planning considering accuracy.