Abstract:Accurate simulations of the temperature field during welding are important for analyzing welding residual stresses and material deformation. The welding temperature field is directly related to the shape parameters of the heat source. However, the heat source shape parameter determination is generally a trial and error process with the efficiency and accuracy highly dependent on the researcher experience. This paper presents an optimization model for determining the heat source parameters during welding which can be used to estimate the shape parameters of various heat sources. Finite element simulations with the optimized parameters compared well with experimental data. The results show that this optimization method reduces the cost of repeated modeling to obtain the optimal heat source parameters, which also reduces the influence of the researchers' experience on the efficiency and accuracy of welding temperature simulations.
[1] DENG D, MURAKAWA H. Prediction of welding residual stress in multi-pass butt-welded modified 9Cr-1Mo steel pipe considering phase transformation effects[J]. Computational Materials Science, 2006, 37(3):209-219. [2] DENG D, MURAKAWA H. Influence of transformation induced plasticity on simulated results of welding residual stress in low temperature transformation steel[J]. Computational Materials Science, 2013, 78:55-62. [3] ZHANG H W, GUI L J, WANG Q, et al. Investigation of residual stress in butt-welded plates considering phase transformation[J]. Proceedings of the Institution of Mechanical Engineers, Part C:Journal of Mechanical Engineering Science, 2021. [4] ZHANG J X, LIU C. Finite element calculation of welding stress and deformation and engineering application[M]. Beijing:Science Press, 2017. (in Chinese)张建勋, 刘川. 焊接应力变形有限元计算及其工程应用[M]. 北京:科学出版社, 2017. [5] GOLDAK J A, AKHLAGHI M. Computational welding mechanics[M]. New York:Springer Verlag, 2005. [6] WEI L, ZHANG L L, WANG P. Numerical simulation on welding process of high-speed train's frame structure based on double elliptical cylinder Gaussian distribution heat source model[J]. Transactions of the China Welding Institution, 2016, 37(12):95-100, 133. (in Chinese)卫亮, 张乐乐, 王鹏. 高速列车框架焊接的双椭圆柱高斯分布热源模型[J]. 焊接学报, 2016, 37(12):95-100, 133. [7] WANG Y, ZHAO H Y, WU S, et al. Shape parameter determination of double ellipsoid heat source model in numerical simulation of high energy beam welding[J]. Transactions of the China Welding Institution, 2003, 24(2):67-70. (in Chinese)王煜, 赵海燕, 吴甦, 等. 高能束焊接双椭球热源模型参数的确定[J]. 焊接学报, 2003, 24(2):67-70. [8] GUO X K. Inversing parameter values of double ellipsoid source model during multiple wires submerged arc welding by using Pattern Search Method[D]. Shanghai:Shanghai Jiao Tong University, 2009. (in Chinese)郭晓凯. 模式搜索法反演多丝埋弧焊双椭球热源模型参数[D]. 上海:上海交通大学, 2009. [9] LI P L. Study on the simulation of multi-wire submerged arc welding heat source model and appearance of weld[D]. Shanghai:Shanghai Jiao Tong University, 2012. (in Chinese)李培麟. 多丝埋弧焊热源模型与焊缝成形的模拟研究[D]. 上海:上海交通大学, 2012. [10] JIA X L, XU J, LIU Z H, et al. A new method to estimate heat source parameters in gas metal arc welding simulation process[J]. Fusion Engineering and Design, 2014, 89(1):40-48. [11] FICQUET X, SMITH D J, TRUMAN C E, et al. Measurement and prediction of residual stress in a bead-on-plate weld benchmark specimen[J]. International Journal of Pressure Vessels and International Journal of Pressure Vessels and Piping, 2009, 86(1):20-30. [12] SHAN X, DAVIES C M, WANGSDAN T, et al. Thermo-mechanical modelling of a single-bead-on-plate weld using the finite element method[J]. International Journal of Pressure Vessels and Piping, 2009, 86(1):110-121. [13] GOLDAK J A, CHAKRAVARTI A, BIBBY M. A new finite element model for welding heat sources[J]. Metallurgical Transactions B, 1984, 15(2):299-305. [14] LINDGREN L E. Finite element modeling and simulation of welding part 1:Increased complexity[J]. Journal of Thermal Stresses, 2001, 24(2):141-192. [15] LINDGREN L E. Finite element modeling and simulation of welding. Part 2:Improved material modeling[J]. Journal of Thermal Stresses, 2001, 24(3):195-231. [16] GARCÍA-GARCÍA V, CAMACHO-ARRIAGA J C, REYES-CALDERÓN F. A simplified elliptic paraboloid heat source model for autogenous GTAW process[J]. International Journal of Heat and Mass Transfer, 2016, 100:536-549. [17] AARBOGH H M, HAMIDE M, FJAER H G, et al. Experimental validation of finite element codes for welding deformations[J]. Journal of Materials Processing Technology, 2010, 210(13):1681-1689.