PSI - Issue 75

Per-Olof Danielsson et al. / Procedia Structural Integrity 75 (2025) 572–580 Per-Olof Danielsson et al. / Structural Integrity Procedia (2025)

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The introduction of the SFM approach simplifies the process of creating CAD models for FE analysis. Previously, with the effective notch stress method, designers had to generate specialized CAD models featuring detailed notches and small radii. In contrast, the SFM approach reduces the complexity required in CAD models and allows the use of coarser FE meshes at welds. This streamlined approach achieves improved performance and reliability while cutting down the time and effort required for CAD and FE model preparation. 3.3. Production Engineering Advancements in manufacturing technology have improved weld quality, production efficiency, and the ability to support fatigue-optimized design solutions. Investments in fiber 3D laser cutting and robotic TIG dressing contribute to consistent weld geometry, better fatigue resistance, and reduced manual labor, while also addressing ergonomic challenges. Key benefits of these technologies include: • Direct beveling and localized weld preparation, • Reduced manual rework and improved ergonomics. and • More consistent welds in both geometry and quality. Improved off-line robot programming supports accurate welding around corners and in tight spaces, improving access and enabling higher automation in complex joints. Robotic TIG dressing, now in its early implementation phase, makes post-weld surface treatment feasible within standard production flows. A growing fleet of welding robots will be supported by a model-based weld management system that ensures alignment with digital design. Fiber 3D laser cutting technology offers a huge energy consumption reduction and enables flexible 3D cutting with beveling. This supports the use of high-strength steels, reducing both welding and overall structural weight — contributing to more sustainable machine production and operation. As an example, shown in Fig. 6, changes in joint types can reduce welding volume, improve robotic welding feasibility, and provide better ergonomics for manual welders. Together, these developments mark a shift toward smarter, more integrated manufacturing processes that support structural performance and sustainability goals. 3.4. Integration – Combining Innovations While each technical area — fatigue analysis, design, and production — has advanced on its own, their integration offers additional system-level benefits. The SFM approach, when combined with modern design practices and production technologies, enhances fatigue prediction for complex welded structures. Key advantages of this integrated approach include: • Direct use of realistic simulated loads in fatigue assessments, • Streamlined CAD-to-FE workflows with minimal manual intervention, and • Manufacturing processes integrated with fatigue-resistant design and standard production flow. Together, these developments lead to shorter development cycles, improved production efficiency, more reliable fatigue life predictions, and reduced structural weight. • Lower energy use and higher cutting speed, Fig. 6. Example of possible change of weld geometry facilitated with the new 3D laser cutting machine.