Optimization of Welding Sequence for Bridge Crane Girder Structure Based on Numerical Simulation

Abstract

Bridge cranes are key equipment in modern industry and logistics. Their manufacturing quality directly affects the safety and service life of the entire machine. The main girders and end beams of such cranes are typically fabricated by welding thick plates. Residual stress and deformation generated during welding are major factors that influence the structural service life and load-bearing capacity. The paper adopts the inherent strain method as the core theory. A mid-surface model of the structure is created using SolidWorks. Two-dimensional mesh discretization and geometry cleanup are performed in Hypermesh. Finally, numerical simulations of different welding sequence schemes are carried out using Sysweld software. During the research, the double ellipsoid heat source model is first calibrated and validated for T-welded joints to ensure the accuracy and applicability of the heat source parameters. Subsequently, simulations are performed according to different welding sequence schemes. Residual stress distribution contours and deformation contours under each scheme are extracted, and a quantitative comparative analysis is conducted on the maximum residual stress, deformations in each direction, and total deformation, leading to the selection of an optimal welding sequence scheme. The simulation results show that different welding sequences have a significant effect on the final residual stress and deformation distribution. Improving the welding sequence can effectively control welding-induced residual stress and deformation, providing guidance for optimizing the welding process of bridge cranes.