Multi-Weld Component Seam Pattern for Fatigue Life Optimization
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Solution Overview
Problem
Existing methods for determining weld lengths in multi-weld components, such as automotive vehicle frames, are inefficient and fail to optimize fatigue performance due to the complexity of numerous weld joints, making it impractical to analyze every possible combination.
Innovation Solution
A method that generates baseline and sensitivity finite element models to analyze variations in weld lengths, reducing the number of calculations by comparing fatigue data between weld pairs and selecting a weld pattern with the highest minimum fatigue life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If finite element modeling is performed on every combination for every length of weld, then measurement precision of fatigue performance is improved, but device complexity and calculation workload increase significantly
Solution Approach 1:
The weld configuration space is segmented into discrete categories (e.g., weld length variations at specific positions) rather than treating all possible combinations continuously. This allows the system to evaluate representative samples from each segment, reducing the total number of FEM analyses required while maintaining measurement precision for fatigue performance.
Solution Approach 2:
Instead of performing exhaustive FEM analysis on every possible weld combination, the method performs partial analysis on a selected subset of representative configurations. This partial action approach captures the essential fatigue performance characteristics without the prohibitive computational cost of complete enumeration.
2Ease of operation
If experience-based engineering judgment is used to determine weld lengths, then ease of operation is improved, but manufacturing precision of optimal weld design deteriorates
Solution Approach 1:
The patent introduces a computational intermediary system that bridges subjective engineering experience and objective optimization requirements. The system codifies expert knowledge into evaluation criteria and uses automated FEM analysis to objectively assess weld configurations, transforming qualitative experience into quantifiable design guidance while maintaining ease of operation.
Data Source
AI summary
A method for determining seam weld length pattern for a component includes generating a baseline finite element model wherein each weld line having a base length, each weld line comprises a first end and a second end. The method also includes generating a first set of finite element models, each of the first set of models having one weld end shortened while all other weld ends at base length, generating a second set of finite element models, each of the second set of models having one weld end lengthened while all other weld ends at base length, generating fatigue data for the baseline finite element model, first and second set of finite element models. Combination models are created by comparing fatigue data between for each weld pair. The method further determines combination model fatigue data for each combination model, determines a minimum fatigue life for each of the combination models from the fatigue data and selects a weld pattern of the combination model having a highest minimum fatigue life value.