Influence of Welding Sequence of T-Rib on Welding Deformation and Residual Stress of Steel Box Girder

Traditionally, the calibration of welding heat source model parameters mainly relies on empirical trial-and-error methods, which lack clear guidance and generally lead to low computational efficiency. To address this problem, this paper establishes a quantitative relationship between heat source parameters and weld pool dimensions, which significantly improves the efficiency and accuracy of the simulation. Furthermore, the influence of laws of key parameters of the double-ellipsoid heat source and welding thermal efficiency on the geometric characteristics of the weld pool is systematically analyzed via numerical simulation. On this basis, finite element models considering different welding sequences are established for single and multiple T-rib components, and appropriate welding process parameters are determined according to the influence laws of heat source parameters. The thermo-elastic–plastic finite element method is then adopted to analyze the effects of welding sequences on the welding residual stress and deformation of T-rib and top-plate joints in steel box girders. By comparing different welding schemes, optimized welding strategies for single and multi-rib welding are proposed. The results show that for single T-ribs, simultaneous welding in the same direction produces the minimum residual stress and deformation with almost no distortion, followed by sequential bilateral welding in the same direction. For multi-rib welding with a spacing of 300 mm, synchronous welding yields the smallest deformation, followed by symmetric double-pass synchronous welding from inside to outside. For continuous single-pass welding, an inside-to-outside skip welding sequence is recommended to effectively control residual stress and deformation.