Perpustakaan Digital ITB

Welding is a process used to join two metal or plastic components by melting them, with or without the use of additional materials. It is a critical technique across various industrial sectors. This process relies on applying heat, pressure, or a combination of both to create strong, durable joints. Welding is widely utilized due to the versatility and extensive applications of metals in industry. However, this technique can introduce residual stresses and deformations that may compromise structural integrity. Welding-induced deformation remains a significant challenge in the fabrication of steel structures, often leading to assembly issues and extended production times. This study focuses on optimizing the welding sequence for a bracket axle component in a dump truck chassis using finite element method (FEM) simulations. A coupled thermo-mechanical analysis was employed to predict temperature distribution and the resulting deformation during multi-layer welding. Three different welding sequences, initial, first modified, and second modified, were simulated and validated through field experiments. The simulations, based on SS400 material properties, incorporated calibrated heat flux values aligned with measured temperature data. Results indicate a significant reduction in deformation up to 38.59% when optimal welding sequences are applied. Field trials confirmed these findings, with the second modified sequence achieving perfect axle alignment in all tested brackets. This study underscores the value of simulation-driven welding optimization in enhancing structural precision and manufacturing efficiency.