Investigation on the Welding Residual Stress Distribution in Multi-Segment Conical Egg-Shaped Shell

The egg-shaped pressure shell, an essential component of manned submersibles, has garnered significant attention from researchers. However, the fabrication of such shells, particularly the welding process used to connect petals or frustums into a shell blank, has raised several concerns. This study investigates the distribution of welding residual stresses in a multi-segment frustum-assembled egg-shaped shell using a thermal–elastic–plastic method under an instantaneous heat source. A numerical model for a 12-segment frustum-welded egg-shaped shell is developed, and welding simulations are performed. The model’s boundary conditions are defined by cyclic symmetry, with a mesh element size of 2 mm to enhance computational efficiency. The results are validated through experimental tests. The findings indicate that the residual stress around the weld is tensile, while compressive stress is present on both sides of the weld. The length of the generatrix and the relative inclination angle significantly affect the distribution and overlap of circumferential residual stress, whereas axial residual stress primarily influences its magnitude. Finally, a simplified numerical model of the egg-shaped shell is proposed, with its simulation results showing good agreement with the distribution of welding residual stresses on the shell surface. This study provides valuable insights for optimizing the welding process of egg-shaped pressure shells in manned submersibles.