How can we calculate safety factor by considering the effect of distortion on the design?
Yes affect, but the proportion is really very difficult to establish. For reduce the uncertainty, the welding work need to be make by an certificate welder.
Yes, it has a significant effect on overall safety factor of a design. Some basic concept you can get from some welding design book:
1.V. M. Radhakrishnan, Welding Technology and Design, New age. 2002
2. Gray T. G. F. and Spence J., “Rational Welding Design”, Butterworths.
I think that distorsions induced by welding which come from the internal stresses generated by the high temperatures involved by the process, mainly cause problems in the expected functionality of the manufactured part. For example, a door that does not close due to distorsions, an assembly that cannot be realized due to parts misalignments, unsightly flatness problems on metal sheets constituting the sides of railway cars, etc.
But, on the other hand, welding residual stresses can very significantly affect the safety factor and should be taken into account during the design stage.
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