Thesis Work: Prediction of Distortion due to Welding in Traction Converters

The thesis project aims to develop a finite element (FE) calculation method for predicting welding-induced distortion. This method integrates welding simulation with structural analysis. The computational approach will be validated through experimental measurements to ensure reliability. Ultimately, the goal is to create a design tool that enables engineers to predict weld distortion early in the development process.

Activities

Introduction to traction enclosure mechanical design.
Understand Structural requirements of railway vehicle bodies, e.g. EN 12663-1
Read and understand the weld modelling methods recommended by literature and across different industries.
Welding Simulation: Thermomechanical simulation to determine residual stresses, to be used as loading for structural analysis. Input required : weld geometry and heat input in kJ/mm.
Structural Analysis: Using stress distribution from welding simulation to determine the mode & magnitude of the deformation of the structure. This includes:
Small deformation analysis: To scale the weld load from weld simulation to the structural analysis.
Eigen value analysis: Estimate structures critical buckling load & distorted shape.
Incremental large deformation analysis: Determine both critical buckling load and distortion magnitude accurately ( only for validating predictive method)