In most variation simulations, i.e. simulations of geometric variations in assemblies, the influence from the heating and cooling processes, generated when two parts are welded together, is not taken into consideration. In most welding simulations the influence from geometric tolerances on parts is not taken into consideration, i.e. the simulations are based on nominal parts. In this paper these two aspects, both crucial for predicting the final outcome of an assembly, are combined by linking two commercial software packages for variation simulation and for welding simulation together. Monte Carlo simulation is used to generate a number of different non-nominal parts in the variation simulation software. The translation and rotation matrices, representing the deviations from the nominal geometry due to positioning error, are exported to the welding simulation software, where the effects from welding are applied. Thereafter, the results from the welding simulation are exported back to the variation simulation software in order to compute and illustrate the deviations and variations of the final subassembly. The method is applied on a simple case, a T-weld joint, with available measurements of residual stresses and deformations. The effect of the different sources of deviation on the final outcome is analyzed and the difference between welding simulations applied to nominal parts and to disturbed parts is investigated.

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