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2 Journal of Achievements in Materials and Manufacturing Engineering

2 2013

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Numerical and experiment study of residual stress and strain in multi-pass GMA welding

Chand R.R., Kim I.S., Lee J. P., Kim Y.S., Kim D. G.

Journal of Achievements in Materials and Manufacturing Engineering

2013

Vol. 57, nr 1

31--37

Purpose: Recently, manufacturing industries have been concentrated on selection an optimal of welding parameter and condition that reduces the risk of mechanical failures on weld structures should be required in manufactory industry. In robotic GMA (Gas Metal Arc) welding process, heat and mass inputs are coupled and transferred by the weld arc to the molten weld pool and by the molten metal that is being transferred to the weld pool. The amount and distribution of the input energy are basically controlled by the obvious and careful choices of welding process parameters in order to accomplish the optimal bead geometry and the desired mechanical properties of the quality weldment. The residual stress and welding deformation have the large impact on the failure of welded structures. Design/methodology/approach: To achieve the required precision for welded structures, it is required to predict the welding distortions at the early stages. Therefore, this study represented 2D Finite Element Method (FEM) to predict residual stress and strain on thick SS400 steel metal plate. Findings: The experiment for Gas Metal Arc (GMA) welding process is also performed with similar welding condition to validate the FE results. The simulated and experiment results provide good evidence that heat input is main dependent on the welding parameter and residual stress and distortions are mainly affected by amount on heat input during each weld-pass. Practical implications: This present study on based on the numerical analysis using ansys software, for a thick multi-pass GMA welding. A birth and death technique is employed to control the each weld pass welding. Originality/value: The developed 2D multi-pass model employs Goldak’s heat distribution, to simulate welding on SS400 steel butt-weld joint with a thickness of 16mm. moreover the numerical results are validated with experiment results.

Development of the intelligent algorithm to control on-line bead height for robotic welding process

Son J. S., Kim I. S., Lee J. H., Park M.H., Jeon G.S.

Journal of Achievements in Materials and Manufacturing Engineering

2013

Vol. 58, nr 2

87--93

Purpose: The demand to increase productivity and quality, the shortage of skilled labour and strict health and safety requirements finally led to the development of the robotic welding process to deal with many problems of the welded fabrication. Many techniques were developed to control process parameters to get the optimal bead geometry during welding process by minimizes their magnitude in the affected area. Design/methodology/approach: The development of thermo mechanical mechanism in some techniques is not fully understood. To solve this problem, we have carried out the sequential experiment based on a Taguchi method and identified the various problems that result from the robotic GMA welding process. Findings: To characterize the GMA welding process and establish guidelines for the most effective joint design. Also using multiple regression analysis with the help of a standard statistical package program, SPSS, on an IBM-compatible PC, a quadratic model has been developed for on-line control which studies the influence of process parameters on bead height and compares their influences on the bead height to see which one of process parameters is most affecting. Originality/value: This model developed has been employed the prediction of optimal process parameters and assisted in the generation of process control algorithms.