Investigation on automated loading of dynamic 3D heat source model for welding simulation

Since programing complex and dynamic heat source model for welding simulation is a complex job,the parametric methods are studied in this paper.Firstly,an overall flow to achieve automatically modeling welding was introduced.Secondly,an expert module rule for selecting welding heat source model was founded,which is based on simulation knowledge and experiences.Thirdly,a modularity routine method was investigated using writing with C++programing,which automatically creates subroutines of 3D dynamic heat source model for user.To realize the dynamic weld path,the local weld path coordinate system was moved in the global coordinate system and it is used to model the direction of weld gun,welding path and welding pose.The weld path data file was prepared by the automatic tool for the welding heat source subroutines.All above functions were integrated in the user interface and the connection with architecture was introduced.At last,a laser beam welding heat source modeling was automatically modeled and the weld pool geometry was compared with the reported literature.It demonstrated that the automated tool is valid for welding simulation.Since modeling became convenient for welding simulation using the tool proposed,it could be easy and useful for welding engineers to acquire the needed information.

MODEL OF LASER-TIG HYBRID WELDING HEAT SOURCE

The welding mechanism of laser-TIG hybrid welding process is analyzed. Withthe variation of arc current, the welding process is divided into two patterns: deep-penetrationwelding and heat conductive welding. The heat flow model of hybrid welding is presented. As todeep-penetration welding, the heat source includes a surface heat flux and a volume heat flux. Theheat source of heat conductive welding is composed of two Gaussian distribute surface heat sources.With this heat source model, a temperature field is calculated. The finite element code MARC isemployed for this purpose. The calculation results show a good agreement with the experimental data.

Finite Element Simulation of Processes Involving Moving Heat Sources. Application to Welding and Surface Treatment

A wide range of welding and surface treatment processes involve the use of a heat source which is moving at a constant speed over the component. The numerical simulation of such processes implies a transient analysis using a very refined mesh in order to follow properly the path of the heat source. The 3D-mesh size can be very large if one consider the welds length or the heat-treated surface size in industrial components. To reduce the computational time to acceptable values, several techniques have been investigated. The first type is to use analytical methods such as Rosenthal equations. The second type of solutions consists in performing a transient analysis using adaptive meshing. But, for a large proportion of the involved processes, practical experience demonstrates the existence of quasi steady state conditions over the major part of the heat source path. Numerical algorithms have therefore been developed to directly compute the steady temperature, metallurgical phase proportion and stress distributions. This paper gives a general overview of the different numerical methods used to simulate welding and surface treatment processes with a special emphasis on the steady state calculation. The benefits and limitations of each of them are discussed and applications are presented.

Heat source analyses of dual laser-beam bilateral synchronous welding for T-joint

The DLBSW（ dual laser-beam bilateral synchronous welding） technology of T-type joint has been widely used for the connection of skins and stringers in airplane industry. To understand the thermodynamic and mechanical behavior of this process, it is necessary to establish a reasonable heat source model. Two different surface-body combination heat source models are adopted in this paper. Both models use the Gaussian surface heat source model and one is combined with the cone body heat source model and the other is combined with Gaussian rotator body heat source model. The simulation results of these two different models are investigated. And the temperature field results of DLBSW process for T-joint with two different heat sources are discussed. It is indicated that the combination heat source model is effective to simulate the DLBSW process and the current study is useful for more profound research in this field.

General expression of double ellipsoidal heat source model and its error analysis

In order to analyze the maximum power density error with different heat flux distribution parameter values for double ellipsoidal heat source model, a general expression of double ellipsoidal heat source model was derived .front Goldak double ellipsoidal heat source model, and the error of maximum power density was analyzed under this foundation. The calculation error of thermal cycling parameters caused by the maximum power density error was compared quantitatively by numerical simulation. The results show that for guarantee the accuracy of welding numerical simulation, it is better to introduce an error correction coefficient into the Goldak double ellipsoidal heat source model expression. And, heat flux distribution parameter should get higher value for the higher power density welding methods.

Cluster banding heat source model

Concept of duster banding heat source model is put forward for the problem of overmany increment steps in the process of numerical simulation of large welding structures, and expression of cluster banding heat source model is deduced based on energy conservation law. Because the expression of cluster banding heat source model deduced is suitable for random weld width, quantitative analysis of welding stress field for large welding structures which have regular welds can be made quickly.

Numerical simulation of gas metal arc welding temperature field

The infrared camera is used to investigate the temperature field of gas metal arc welding. The results show that the temperature distribution of weld pool and adjacent area appears cone shape. A new heat source model combined by Gaussian distribution heat source of the arc and conical distribution heat source of the droplet is set up based on the experimental results, and with the combined boundary conditions, the temperature field of gas metal arc welding is simulated using finite element method. According to the comparison between the results of experiment and simulation in temperature field shows that the new combined heat source model is more accurate and effective than the Gauss heat source model.

Modelling of the plasma-MIG welding temperature field

A three-dimensional simulation model for the plasma-MIG welding process, which takes the interaction between the plasma arc and MIG arc into account, is presented and the quasi-steady temperature fields on the workpiece are calculated with the model. The 10 mm-5A06 aluminum alloy is welded and the temperature fields are measured with the thermoelectric couple. The simulation results and measured results show that the biggest deviation of peak temperature between them is below 20 ℃, which indicates good coincidence between the simulation and measurement.

Numerical simulation of dynamic thermal process during doublesided asymmetrical TIG backing welding of large thick plates

The dynamic thermal process during double-sided asymmetrical TIG backing welding of large thick plates （ 1 000 mm×700 mm×50 mm） is numerically simulated using MSC. MARC. The effect of arc distance on the thermal cycle in weld zone during double-sided asymmetrical T1G backing welding is investigated. The results show that the workpiece experiences double-peak thermal cycle in double-sided asymmetrical TIG backing welding. On the one hand, the fore arc has the pre- heating effect on the rear pass, and the pre-heating temperature depends on the distance between the double arcs, the heat input of fore arc, and the initial temperature of workpiece. On the other hand, the rear arc has the post-heating effect on the fore pass. The mutual effects of two heat sources decrease with the increase of arc distance.

Numerical simulation of temperature field in deep penetration laser welding of 5A06 aluminum cylinder

Deep penetration laser welding temperature field of 5A06 aluminum alloy canister structure was simulated using the surface-body combination heat source model by ANSYS, which was made up of Gauss surface heat source model and Gauss revolved body heat source model. Convection, radiation and conduction were all con,sidereal during the simulation process. The thermal cycle curves of the points both on the shell outer surface and in the seam thickness direction were calculated. Simulated results agreed well with the experiment results. It concluded that the surface-body combination heat source model was fit for the temperature field simulation of deep penetration laser welding of the aluminum alloy canister structure. This method was proved to be an efficient way to predict the shape and dimension of welded joint for deep penetration laser welding of the aluminum alloy canister structure.

Finite element simulation of three-dimensional temperature field in underwater welding

Mathematical models of three-dimensional temperature fields in underwater welding with moving heat sources are built. Double ellipsoid Gauss model is proposed as heat sources models. Several factors which affect the temperature fields of underwater welding are analyzed. Water has little influence on thermal efftciency. Water convection coefftcient varies with the temperature difference between the water and the workpiece , and water convection makes molten pool freeze quickly. With the increase of water depth, the dimensions of heat sources model should be reduced as arc shrinks. Finite element technology is used to solve mathematical models. ANSYS software is used as finite element tool, and ANSYS Parametric Design Language is used to develop subprograms for loading the moving heat sources and the various convection coefftcients. Experiment results show that computational results by using double ellipsoid Gauss heat sources model accord well with the experimental results.

Theoretical and experimental investigation of gas metal arc weld pool in commercially pure aluminum:Effect of welding current on geometry

Effects of welding current on temperature and velocity fields during gas metal arc welding(GMAW) of commercially pure aluminum were simulated. Equations of conservation of mass, energy and momentum were solved in a three-dimensional transient model using FLOW-3 D software. The mathematical model considered buoyancy and surface tension driving forces. Further, effects of droplet heat content and impact force on weld pool surface deformation were added to the model. The results of simulation showed that an increase in the welding current could increase peak temperature and the maximum velocity in the weld pool. The weld pool dimensions and width of the heat-affected zone(HAZ) were enlarged by increasing the welding current. In addition, dimensionless Peclet, Grashof and surface tension Reynolds numbers were calculated to understand the importance of heat transfer by convection and the roles of various driving forces in the weld pool. In order to validate the model, welding experiments were conducted under several welding currents. The predicted weld pool dimensions were compared with the corresponding experimental results, and good agreement between simulation and preliminary test results was achieved.

Simulation of inverse heat conduction problems in fusion welding with extended analytical heat source models

The paper presents bounded volume heat sources and the corresponding functional-analytical expressions for the temperature field. The power density distributions considered here are normal, exponential and parabolic. The sources model real heat sources like the welding arc, laser beam, electron beam, etc., the convection in the weld pool as well as the latent heat due to fusion and solidification. The parameters of the heat source models are unknown a priori and have to be evaluated by solving an inverse heat conduction problem. The functional-analytical technique for calculating 3D temperature fields in butt welding is developed. The proposed technique makes it possible to reduce considerably the total time for data input and solution. It is demonstrated with an example of laser beam welding of steel plates.

Numerical analysis of thermal process in continuous drive radial friction welding

A heat source model for radial friction welding was proposed, which was determined by friction pressure, friction coefficient, material properties and extrusion speed of material. A 3D model was established to analyze the continuous drive radial friction welding temperature field of 45 steel pipe. The influences of friction pressure, friction time and rotation speed on the temperature of the friction interface were analyzed. The results showed that the temperature on the friction interface rapidly rose to a peak temperature in initial friction stage and kept constant in the stable friction stage. Welding parameters of friction pressure, friction time and rotation speed had few influences on the peak temperature, while the increase of frlctlon pressure and rotation speed could shorten the time to reach the peak temperature.

Welding thermal characteristics analysis with numerical simulation for thin-wall parts assembly under different conditions

In order to analyze the welding thermal characteristics problem,the multiscale finite element(FE)model of T-shape thin-wall assembly structure for different thicknesses and the heat source model are established to emphatically study their welding temperature distributions under different conditions.Simultaneously,different welding technology parameters and welding directions are taken into account,and the fillet weld for different welding parameters is employed on the thin-wall parts.Through comparison analysis,the results show that different welding directions,welding thicknesses and welding heat source parameters have a certain impact on the temperature distribution.Meanwhile,for the thin-wall assembly structure of the same thickness,when the heat source is moving,the greater the moving speed,the smaller the heating area,and the highest temperature will decrease.Therefore,the welding temperature field distribution can be altered by adjusting welding parameters,heat source parameters,welding thickness and welding direction,which is conducive to reducing welding deformation and choosing an appropriate and optimal welding thickness of thin-wall parts and relative welding process parameters,thus improving thin-wall welding structure assembly precision in the actual large-size welding structure assembly process in future.

辅丝对摇动电弧窄间隙GMA焊接温度场的影响

【目的】旨在建立主辅丝同步的摇动电弧窄间隙GMA焊温度场模型。【方法】从宏观传热学出发,综合考虑横断面几何形状特征、主丝和辅丝的运动及焊缝表面形状对电弧热流分布特征的影响,并利用ANSYS软件对不加辅丝和主辅丝同步摇动两种情况下的电弧瞬态温度场及热循环曲线进行了模拟计算。【结果】焊缝横断面的计算结果、测温特征点热循环曲线的计算结果,与试验结果接近。【结论】证明模型可以真实反映添加辅丝的摇动电弧的移动轨迹及分布特征,具有较高的准确性。不加辅丝时,焊缝横断面底部有明显“双峰”特征,主辅丝同步摇动时,“双峰”特征明显减弱。主辅丝同步摇动情况下的热影响区宽度略有增加。

具有防融霜装置的蒸发器结霜特性及性能仿真研究

以具有防融霜装置的蒸发器为研究对象,建立基于理想最小防融霜补热量和结霜量无量纲关联式的空气源热泵动态模型,并依据实验数据验证其精确性,通过数值模拟分析不同环境参数对具有防融霜装置的蒸发器性能的影响。结果表明:后置式与跨越式系统蒸发器换热系数要高于前置式与传统电辅热系统,霜层厚度更小,分布更均匀;当相对湿度一定时,蒸发器换热系数随温度升高而增大;当空气温度不变时,换热系数随相对湿度的下降而减小,霜层更均匀;温度对蒸发器换热系数的影响比相对湿度更大。

一种考虑光伏发电与峰谷电价的空气源热泵最优装机容量计算方法

针对目前光伏发电及峰谷电价的用电形式下,空气源热泵耦合电锅炉供热系统经济性装机容量选择困难的有关问题,提出一种综合考虑光伏发电与峰谷电价影响的设备装机容量计算方法,使用空气源热泵最优不保证天数(OGD)作为选型参考值,通过TRNSYS建立系统模型开发新模块使其具有自动寻优能力。在使用测试数据验证模型准确性后,基于该模型计算5座代表性城市OGD推荐值。结果表明:OGD值受建筑负荷大小与光伏装机容量双重影响。采用OGD均值作为推荐值时,单一建筑OGD与均值分别对应的费用年值最大误差为8.17%,可保证计算准确性;5类气候分区内各城市费用年值变化规律基本一致,OGD值随气候变暖各气候分区间平均下降46.83%;其中北京市最大OGD值仅为5,说明在寒冷B区城市此类系统添加光伏发电后,可不设置辅助热源。

Research on modeling of heat source for electron beam welding fusion-solidification zone

In this paper, the common heat source model of point and linear heat source in the numerical simulation of electron beam welding （EBW） were summarized and introduced. The combined point-linear heat source model was brought forward and to simulate the welding temperature fields of EBW and predicting the weld shape. The model parameters were put forward and regulated in the combined model, which included the ratio of point heat source to linear heat source Qpr and the distribution of linear heat source Lr. Based on the combined model, the welding temperature fields of EBW were investigated. The results show that the predicted weld shapes are conformable to those of the actual, the temperature fields are reasonable and correct by simulating with combined point-linear heat source model and the typical weld shapes are gained.

基于粒子群算法确定热源参数的EH40/316L高功率激光焊接温度场模拟

焊接瞬态温度场对焊接残余应力与变形模拟结果具有重要的影响,为提高EH40/316L高功率激光焊接的温度场模拟精度,开发了用于热源模型经验参数优化的智能计算方法.该方法利用MATLAB软件随机生成热源模型的经验参数,调用ANSYS软件执行焊接温度场模拟的APDL命令,并在计算完成后返回结果数据,然后通过借助粒子群算法的群体智能和进化智能的优点,根据预测结果生成新的热源经验参数,进行迭代计算,直至预测结果为最优结果;同时,为提高收敛速度,将有限元几何模型简化为原模型的1/5.基于该方法,开展了10个热源模型经验参数优化案例的计算,并根据优化结果分析了热源模型的参数敏感性.结果表明,该方法实现了温度场的准确预测,其中10个优化案例的平均计算时间为30.3 h,最大、最小和平均预测误差分别为2.84%,2.06%和2.16%;同时,由预测误差和热源经验参数的响应曲面可知,两者之间具有复杂的非线性关系,其数学函数为多谷函数.