ABSTRACT During ship design, welding-induced distortions are roughly estimated as a function of the size of the component as well as the welding process and residual stresses are assumed to be locally in the range of the yield stress. Existing welding simulation methods are very complex and time-consuming and therefore not applicable to large structures like ships. Simplified methods for the estimation of welding effects were and still are subject of several research projects, but mostly concerning smaller structures. The main goal of this paper is the application of a multi-layer welding simulation to the block joint of a ship structure. When welding block joints, high constraints occur due to the ship structure which are assumed to result in accordingly high residual stresses. Constraints measured during construction were realized in a test plant for small-scale welding specimens in order to investigate their and other effects on the residual stresses. Associated welding simulations were successfully performed with fine-mesh finite element models. Further analyses showed that a courser mesh was also able to reproduce the welding-induced reaction forces and hence the residual stresses after some calibration. Based on the coarse modeling it was possible to perform the welding simulation at a block joint in order to investigate the influence of the resulting residual stresses on the behavior of the real structure, showing quite interesting stress distributions. Finally it is discussed whether smaller and idealized models of definite areas of the block joint can be used to achieve the same results offering possibilities to consider residual stresses in the design process.
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