Welding distortion generated uncertainties in the vibrational behavior of a ladder-like structure

Recent developments in acoustic simulation methods allowed engineers to assess the vibroacoustic behavior of various type of structures within a virtual environment, thus allowing the replacement of prototype-based development with simulations. However, there are some factors, that cannot be considered in simulations in advance. In the present study, the effect of the distortions generated due to welding on a ladder-like structure equipped with flat plates was investigated. The measured acceleration frequency response functions were compared to finite element simulation results. The measured responses differed significantly from the simulation, even in the low frequency range, where the global modes were not expected to be altered or vanished. Investigation of the simulated results revealed that the additional modes were related to the vibration of the plates, which were assumed to be flat, instead of considering the warping caused by the welding process. After measuring the approximate deformation of the plates, an updated simulation model was made, introducing an approximate curvature in them. The results obtained with the updated simulation model performed much better in the low frequency range as well as in the third octave-averaged frequency bands up 1200 Hz. The sensitivity of the warping was also systematically evaluated.