ARTICLE IN PRESS

International Journal of Mechanical Sciences 49 (2007) 11221129

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Analysis of angular distortion in line-heating

K.J. Sona, J.O. Yunb, Y.W. Kimc, Y.-S. Yangb,
a
Radioisotope Research Laboratory, Korea Atomic Energy Research Institute, 150 Dukjindong, Yuseong-gu, Daejeon 300-600, South Korea
b
Department of Mechanical Engineering, Chonnam National University, 300 Yongbongdong, Bukgu, Gwangju 500-757, South Korea
c
Military Vehicle ILS Team, Kia Motors Corporation, 700 Naebangdong, Seogu, Gwangju 502-711, South Korea
Received 26 May 2006; received in revised form 20 February 2007; accepted 25 February 2007
Available online 12 March 2007

Abstract

A simplied analytical model for prediction of deformations of metal plates due to line-heating process is presented. In the present
work, a formula for plate deformation produced by line-heating in terms of process parameters such as heat input and plate dimensions
is developed analytically using an eigenstrain concept. The residual deformation due to thermal processing was depends on the
magnitude and region of plastic strains at heating zone. The magnitude of plastic strains was determined by disk model and its region was
calculated using the Rosenthals solution. The vertical displacement of the plate was analysed by using an innite laminated plate theory
to consider a cuboidal inclusion with an eigenstrain. Comparison of calculated results and experimental data shows the accuracy and
validity of proposed model.
r 2007 Elsevier Ltd. All rights reserved.

Keywords: Eigenstrain; Plastic strain; Circular model; Line heating

1. Introduction generated by non-uniform temperature gradient, which

Line heating is an important production process that is
widely used to produce various curved thick plate for ship
industry [13]. In ship building, it has been an important
problem in manufacturing process. Many researches have
focus on the prediction of the shape of the metal plate,
when the line-heating condition and material properties are
known [413]. In order to calculate the shape of plate, nite
element method or plate theory is applied. Research on
design of the proper heating and cooling processes is based
on the experience of forming simple shape surfaces from
rectangular plates [1418]. In order to determine heating
line, strain or curvature analysis is needed. It is thought
that process automation can be possible, using differential
geometry and numerical analysis. In shipbuilding industry,
plates are so thick that temperature gradient is the main
mechanism which induces the bending of thick plates in
line-heating process. Thermal strains and stress are
Corresponding author. Tel.: +82 62 530 1675; fax: +82 62 530 1689.
E-mail address: ysyang@chonnam.ac.kr (Y.-S. Yang).
are produced in the plate by the heating and cooling cycles
that occur in the line-heating process. Line-heating process
is very complex transient thermo-elasticplastic procedure,
and the predictions of residual deformation are relatively
difcult. Also computation time is very long in case of
three-dimensional nite element analysis [19,20]. There-
fore, three-dimensional model is not suitable for real time
analysis. In order to reduce computation time, simplied
models have been developed, but there are more work
needs to be done to apply it in the line-heating process [6,7].
In this paper, weld-induced angular distortions formula,
which is composed of weld parameter such as heat input and
plate thickness, is developed analytically by the use of an
elliptic cylindrical inclusion with an eigenstrain in an innite
laminated plate theory. Angular distortion is dominated by
the distributions of plastic strains in weldments. It is assumed
that plastic strains, driving force to make welding distortion,
are produced in a critical heating region. Plastic strains and its
region correspond to eigenstrains and size of inclusion. In
order to verify the calculations, calculated results are
compared with experimental data.

0020-7403/$ - see front matter r 2007 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijmecsci.2007.02.008
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K.J. Son et al. / International Journal of Mechanical Sciences 49 (2007) 11221129 1123

Nomenclature sy tangential stress of the disk

syl yield stress of the plastic region
x1 ; x2 ; x3 plate-xed rectangular coordinate system E1 Youngs modulus of the disk
x; x2 ; x3 moving rectangular coordinate system E2 Youngs modulus of the plate
T temperature a radius of the plastic region
T0 initial temperature a thermal expansion coefcient
Tc critical temperature n Poissons ratio
Q heat ux n1 Poissons ratio of the disk
k thermal conductivity n2 Poissons ratio of the plate
l thermal diffusivity K equivalent spring constant
v travel speed of heat source u3 out of plane displacement of the plate
 residual plastic strain dkl Kronecker delta
r radial strain of the disk b minor axis of ellipsoid
r radial eigenstrain of the disk R x2 x22 x23 1=2
y tangential strain of the disk Rn x2 x22 2nh  x3 1=2
pm plastic strain of the disk R0n x2 x22 2nh x3 1=2
sr radial stress of the disk

2. Plate deformations in line-heating process

Deformations in line-heated plate are produced as a

result of plastic deformation, which is caused by non-
uniform temperature distributions in the work piece. It is
problematic to determine the size and magnitude of plastic
strains because line-heating process is highly complex
transient thermo-mechanical problem. In the present
paper, it is assumed that plastic strains occurring during
the line-heating process are generated in a critical
Fig. 1. Schematic gure showing the temperature distribution in a plate
temperature region. The critical temperature region can when a point heat source is travelled on the surface.
be considered as the plastic strain generation region
because although plastic strains might be created below
the critical temperature, the bulk of plastic strains are Eq. (1) can be written as
produced above this critical temperature. Generally, the
mechanical and physical properties of metal are tem-  2 
qT q T q 2 T q2 T
perature dependent. As the temperature of the line-heated rc Q_ G k
qt qx2 qx22 qx23
area increases, the yield strength, modulus of elasticity " 1   2  2 #
and thermal conductivity of steel are decreased, whereas qk qT 2 qT qT
. 2
the specic heat and the coefcient of thermal expansion qT qx1 qx2 qx3
are increased. In particular, yield strength, i.e. the limit
of elasticity, and Youngs modulus, which expresses If the value of thermal conductivity does not change with
the resistance of the material to deformation by an ex- temperature, or qk=qT 0, Eq. (2) can be reduced to
ternal force, decrease severely above the critical tempera- linear differential equation:
ture. To determine the critical temperature region, we  2 
used following equations describing temperature distribu- qT _ q T q 2 T q2 T
rc QG k . (3)
tions [21]. qt qx21 qx22 qx23
Fig. 1 shows schematically the temperature distribu-
tion in a plate when a surface weld bead is being laid at a If there is no heat sink or source in the element concerned
speed v. The fundamental equation of heat conduction in a or Q_ G 0, Eq. (3) can be further reduced to
solid is  2 
qT q T q2 T q2 T
l . (4)
qt qx21 qx22 qx23
     
qT q qT q qT q qT
rc Q_ G k k k . Mathematical analyses of heat ow in welding in quasi-
qt qx1 qx1 qx2 qx2 qx3 qx3 stationary state have been made by many investigators
(1) [22,23].
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1124 K.J. Son et al. / International Journal of Mechanical Sciences 49 (2007) 11221129

Using a coordinate w; x2 ; x3 , which moves at the same simplied mechanical model with the following assump-
speed as the heat source, as shown in Fig. 1: tions.
w x1  vt. (5)
The temperature undergoes no change in the new system of (1) The elasto-plastic process is concentrated on a circular
a moving coordinate, thus Eq. (4) is expressed as follows: disk under the heat source and that the plate is innite
 2    in two dimensions. Also, the diameter of the disk
q T q2 T q2 T v qT
 . (6) changes through the thickness of the plate, resulting in
qw2 qx22 qx23 l qw elliptical isothermal boundaries in the cross section of
Eq. (6) is more easily handled by replacing it with the the plate perpendicular to the direction of the heating
following expression: line.
(2) The thermal elasto-plastic process occurs within the
T T 0 ev=2lw fw; x2 ; x3 , (7) small, circular region axisymmetrically and the remain-
where T 0 initial temperature, fw; x2 ; x3 function to ing elastic region resists the expansion and contraction
be found. of the circular plastic region. The resistance of the
Since the source is a point source, the heat ux through elastic region on the plastic zone is modelled as a set of
the surface of the hemisphere drawn around the source surrounding springs that is illustrated in Fig. 2. The
must tend to the value of the total heat, Q, delivered to the spring constant K is evaluated by deriving the radial
plate, as the radius of the sphere tends to zero. displacement of a circular hole of an innite plate
Mathematically speaking, if R is the radius of the sphere, subjected to an inner uniform pressure p, as shown in
Fig. 2.
qT (3) The temperature increasing process, which results in
lim 2pR2 k QP . (8)
R!0 qR thermal expansion, can be thought of, as a mechanical
We can obtain the temperature distribution in a plate of plastic loading in the plastic region and the temperature
nite thickness, h, from the former solution by neglecting decreasing process is a mechanical plastic unloading.
the radiation and convection from the surface. The This plastic unloading process is the cause of the
condition on the surface is residual strains, which ultimately result in the plate
angular deformation.
qT
0 for x3 0 and x3 h. (9) (4) The nal angular deformation results from the integra-
qx3 tion of deformation due to the residual strain in each
The solution is obtained as follows. It is the solution that disk. The bounds of integration are dened by the
the point heat source travels the plate having nite region of inherent strain produced during heating,
thickness and innite breadth and width which is assumed to have an elliptical distribution in
 the plane of the plate perpendicular to the heating path.
Q vx=2l ev=2lR The assumed elliptical distribution is based on experi-
T  T0 e
2pk R mental results and Rosenthals solution.
#
X1  v=2lRn 0 
e ev=2lRn
. 10
n1
Rn R0n
Under the above assumptions, during the tempe-
Since the deformations by line-heating have very rature increasing process, the central circular area sur-
complex transient thermo-mechanical behaviour, we in- rounded by elastic spring, becomes plastic. During
troduced the simplied model. Jang et al. [10] proposed a the heating process, the stressstrain relations of circular

p
2a

Fig. 2. (a) Model of plastic region, (b) model of elastic region.

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K.J. Son et al. / International Journal of Mechanical Sciences 49 (2007) 11221129 1125

area are as follows: eigenstrain 0ijn and the eigencurvature kij have the form:
0ijn 0n dij and kij k dij , which is a typical case of
du1 1
r sr  n1 sy r , (11) thermal eigenstrain in an isotropic material. Using the
dr E1 relation H ik;k H ;i , we obtain from Eq. (18)
u1 1 1n  2
y sy  n1 sr y . (12) u3  ~
k a1 w, (19)
r E1 2
The radial displacement of circular area is
  1
1 w~ Hx1 ; x2  H0; 0. (20)
u1 1  n1 s1  r. (13) pa21
E1
Since the eigenstrain  is assumed to vary only through
The spring constant of the surrounding area is determined
the thickness, the eigencurvature in Eq. (19), having effect
by
on the displacement, is produced. In this study, since we
E2 assumed that the welding plastic strain is uniform through
K . (14)
a1 n2 the thickness direction and it exists only the region in
The stress of boundary between circular area and innite critical temperature, eigencurvature is generated. The
plate is expressed by laminated plate consisted of two laminae and one of two
laminae contains inclusion with uniform eigenstrains.
 aK When the top lamina thickness h1 is equal to inclusions
s . (15)
1 1  n1 =E 1 Ka thickness h3 , the inclusion can be regarded as deformed
During the heating process, the plastic strains of circular zone (Fig. 4) and eigencurvature is determined as follows
area are as follows: Z 3 2 0
C 11 C 12 h h h 
pm aT c . (16) k  x3 dx3 , (21)
D11 D12 h2 h0
After the cool down, the plastic strain is determined by where extensional stiffness tensors C 11 and C 12 are given by
difference of heating plastic strains and cooling elastic C 11 E=1 R n02 , C 12 nE=1  n2 , and bending stiffness
strains, and it is expressed in h
tensor Dij is h0 C ij x23 dx3 ij 11; 12, and eigencurvature
 
 1 1  n1 is dened as k11 k22 k .
 aT c  syl . (17) In order to calculate the out-of-plane displacement of the
aK E1
line-heated plate, which is obtained by substituting the
Consider a deformation of an innite plate composed of magnitude and region of plastic strains in Eq. (19), the
thin layers of isotropic linear elastic materials. The cross region of plastic strains is approximated as shown in Fig. 5.
section of such a plate is shown schematically in Fig. 3. The Semi-ellipse region, which obtained from the Rosenthals
plate has a constant thickness h. An eigenstrain  is
prescribed in a cuboidal inclusion with a height h and a x3
constant elliptic cross section O. The eigenstrain  is
assumed to vary only through the thickness [24].
Since plate and inclusion are homogeneous, the expres-
sion of the displacement of thickness direction for exterior
points is written as x1
h(1)
h
1 h(3)
u3  f1 nD Hdkl 1  nD H kl gkkl , (18)
4p
where nD D12 =D11 . H and H kl are the introduced
h(2) h0
integrals [24].
Next, we consider the rectangular inclusion with a
dilatational eigenstrain as a special case. The main plane Fig. 4. Eigenstrain in one lamina.

Fig. 3. Innite plate containing a cuboidal inclusion with an eigenstrain.

 ARTICLE IN PRESS
1126 K.J. Son et al. / International Journal of Mechanical Sciences 49 (2007) 11221129

solution, is assumed in rectangular region of the same Substituting Eq. (22) representing the eigencurvature in
area. The width of rectangular inclusion is determined by Eq. (19), we obtain the out-of-plane deformation of line-
xed depth b. Therefore, eigencurvature in Eq. (21) is heated plate as follows:
expressed by  
31 nb 0 pb
u3  h 
    03 8
3pb 1 1n pb  16h  
k 3 aT c  syl h0  . (22) 1 1n
8h0 Ka E 8  aT C  syl Hx1 ; x2  H0; 0. 23
Ka E

plastic zone
2a
Table 1
b Thermal and mechanical properties of plate

Properties Value

base metal Thermal expansion 11:6  106 mm=mm  C

Yield strength 30:0 kg=mm2
Critical temperature 800  C
plastic zone Room temperature 20  C
Poissons ratio 0.3
2a Density 7:8  106 kg=mm3
Specic heat 486:0 J kg= C
Thermal conductivity 51:9  103 J=s mm C
b / 4
base metal
300
Fig. 5. Approximation of plastic region.

200
y

100
y(mm)

x -100
200

-200

150 150 150

450 -300
-300 -200 -100 0 100 200 300
x(mm)

Fig. 6. Specic diagram of III shape specimen. Fig. 8. Contour of vertical displacement in triple parallel line heating.

Fig. 7. Schematic drawing of experimental setup for vertical deformation of plate by using coordinate measuring machine.
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K.J. Son et al. / International Journal of Mechanical Sciences 49 (2007) 11221129 1127

3. Results and discussions This gure shows that local deformed shape is concen-
trated on the area near the heating lines like Fig. 9. Fig. 14
Two kinds of experiments were conducted to verify the shows the vertical displacement by experiment and
proposed method that can quantitatively predict deformed calculation in the case of K shape heating lines. The
shape of line-heated plate. The GTA welding was used as general trends and values of vertical displacement obtained
heat source and its travel speed was 4 mm/s and other welding by proposed method are good matched with experimental
conditions are shown in Table 2. In the rst case, the plate data in 12% and 8% error bound.
was heated along the three parallel lines (Fig. 6) and vertical When the plate is much large comparing to the size of
displacements of plate were measured by the coordinate heating line, the plate can be assumed to be innite and it is
measuring machine as shown in Fig. 7. And the physical and
mechanical properties of plate that are used for calculating Table 2
the vertical displacement are shown in Table 1. Figs. 8 and 9 Welding conditions
are showing the vertical displacement contour and deformed
Conditions Value
shape of plate calculated by proposed method in triple
parallel line heating, respectively. Experimental and analytical Travel speed 4 mm=s
results in the rst case are shown in Fig. 10. These results Voltage 15 V
show good agreement within 5% and 7% error bound Current 150 A
Efciency 0.5 (50%)
between experiments and analysis of proposed method.
Plate thickness 10 mm
The second case has three heating lines that are located
K shape (Fig. 11). Contour of vertical displacement in the
second case is shown in Fig. 12. Deformed shape of vertical y
displacement in K shape line-heating is shown in Fig. 13.

4 x
x3

2
0
200
-300 -300
-200 -200
-100 -100
0 0
y(m 100 100 200 200
m) m)
200 200 x(m
300 300

Fig. 9. Deformed shape of vertical displacement in triple parallel line

heating. Fig. 11. Specic diagram of K shape specimen.

5
Measuring data
Analytical soultion
4
Vertical displacement (mm)

+7% line of calculation

3

2
-5% line of calcuation

0
-300 -200 -100 0 100 200 300
x (mm)

Fig. 10. Vertical displacement of the plate at y 0 (III shape).

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1128 K.J. Son et al. / International Journal of Mechanical Sciences 49 (2007) 11221129

300 predicted that analytic results agree well with experiment.

But the plate is not enough large comparing to the size of
heating line, the plate cannot be assumed to be innite,
200
therefore calculated vertical displacement cannot be con-
vinced to agree well with the experimental data. This
100
reason caused that the results of the case of three parallel
lines are more accurate than K shape heating.
Line-heating process includes complex thermo-elastic
y(mm)

0 plastic procedure, and the calculation of thermal deforma-

tion is not simple. Finite element analysis is often used to
perform thermo-mechanical analysis. But transient ther-
-100 mo-mechanical analysis is very complex and computation
time is very long. Also application is not simple to predict
residual deformation. In the proposed analytic model,
-200
elastic analysis can be used in place of thermo-elastic
plastic analysis, therefore this model does not need much
-300 computation time and application is simple. Simplied
-300 -200 -100 0 100 200 300 analytic model is concerned with elastic eld in a cuboidal
x(mm) inclusion with eigenstrains in an innite plate. Calculated
result having direction of perpendicular to the heating line,
Fig. 12. Contour of vertical displacement in K shape line-heating.
such as Fig. 10, agrees well with experimental results.
Because the distance is far enough from the heating line
and the plate is close to innite. Conversely, calculated
vertical displacement along to the heating line such as
Fig. 14 does not agree well with experiment comparing to
Fig. 10. In this case, the distance is not far enough from the
heating line. In most of line-heating process, the distance
directed along to the heating line is small. For this reason,
4 modication is need for the vertical displacement directed
x3

2 along to the heating line. Therefore, it is known that good

0
-300 -300 agreement is achieved in Fig. 10 comparing to Fig. 14. By
-200 -200
means of analytical model, vertical displacement can be
-100 -100
0 0 predicted in place of thermo-mechanical analysis. Espe-
y(m 100 m) cially, calculated vertical displacement directed perpendi-
m) 100 x(m
200 200
cular to the heating line can be used usefully. But further
300 300
research is required to modify the analytic model for the
Fig. 13. Deformed shape of vertical displacement in K shape line heating. vertical displacement directed along to the heating line.

4
Measuring data
Analytical soultion

3
Vertical displacement (mm)

+8% line of calculation

-12% line of calcuation

1

0
-300 -200 -100 0 100 200 300
x (mm)

Fig. 14. Vertical displacement of the plate at y 0 K shape.

 ARTICLE IN PRESS
K.J. Son et al. / International Journal of Mechanical Sciences 49 (2007) 11221129
4. Conclusions
An analytical solution for plate deformations of line-
heating process in terms of heat input, material properties
and plate thickness only has been developed, using the theory
of deformation of a plate containing an inclusion with
eigenstrains. Two cases of line-heating process are performed
in experiments and analysis. Local deformed shape is
concentrated on the area near the heating lines and whole
vertical displacement results from local deformed shape near
the heating lines. Fairly good agreement between the
calculated and experimental results has been achieved.
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