A review of welding simulation methods for large components

The challenges posed by cross-scale effects, large computational requirements, high nonlinearity, and complex interactions of multiple physical phenomena constitute major obstacles to the effectiveness and accuracy of welding simulations for large structural components. Therefore, achieving accurate welding simulation to predict and effectively control welding deformation of substantial engineering structural parts is essential to ensure welding quality and improve production efficiency. This paper reviews the current research status of welding numerical simulation of large engineering components, including the establishment of the finite element model, optimization of the heat source model, selection of appropriate finite element calculation method, and the control of welding deformation through optimization algorithm. In addition, the strategies to improve the precision and efficiency of welding numerical simulation and control welding deformation of engineering components are analyzed and discussed. The future development of welding numerical simulation will focus on balancing simulation accuracy and simulation efficiency and optimizing welding parameters to control welding deformation efficiently.