Design and Application of the Stretching Technology on the Welding Process of Stiffened Sheet Metal Structure

Heru Sukanto; Triyono Triyono; Nurul Muhayat

doi:10.4028/www.scientific.net/AMM.493.541

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HomeApplied Mechanics and MaterialsApplied Mechanics and Materials Vol. 493Design and Application of the Stretching...

Design and Application of the Stretching Technology on the Welding Process of Stiffened Sheet Metal Structure

Abstract:

Stiffened sheet metal structure where sheet metal is reinforced by frame has been claimed as the most effective structure because it has low volume and weight. It is generally applied to large car body structure such as bus and train body. Frame and sheet are commonly joined by welding process. Due to the local heating of welding, distortion or deformation will occur in this structure. To mitigate this distortion, new method called stretching technology was proposed in this work. In this method, sheet was stretched to certain pre-strain, kept in this condition and then welded to frame. Special equipment powered by hidroulic system was designed to support this method. Low carbon steel SPAC specimens with dimension of 400mm, 1824mm and 3mm in width, length and thick respectively were prepared to evaluate the method. Hidroulic power was controlled to meet the sheet pre-strain variations of 0.00%, 0.05%, 0.10% and 0.15%. The distortion of the specimen was measured by dial indicator with mesh point of 50mm and shown in 2D contour chart. The study results revealed that the welding process on the sheet without pre-strain had the highest distortion of 8.34mm while that with pre-strain of 0.05% provided the lowest distortion of 3,3mm or 60% lower than without pre-strain specimen. The pre-strain of 0.10% and 0.15% produced the sheet distortion of 7.05mm and 7.9mm respectively. The excessive pre-strain was an ineffective method to mitigate the welding distortion because the reverse tension force of sheet would destroy the weld joint when the hydraulic force was released.