Three-dimensional numerical study of heat-affected zone in induction welding of tubes

2020 ◽  
Vol 39 (1) ◽  
pp. 213-219
Author(s):  
Prerana Das ◽  
John Inge Asperheim ◽  
Bjørnar Grande ◽  
Thomas Petzold ◽  
Dietmar Hömberg
Keyword(s):  
Process Parameters ◽  
Material Properties ◽  
High Frequency ◽  
3D Model ◽  
Welding Process ◽  
Induction Coil ◽  
Content Type ◽  
Non Linear ◽  
Tube Welding ◽  
Welding Line

Purpose Quality of the weld joint produced by high-frequency induction (HFI) welding of steel tubes is attributed to a number of process parameters. There are several important process parameters such as the speed of the welding line, the angle of the approaching strip edges, the physical configuration of the induction coil, impeder, formed steel strip and weld rolls with respect to each other, the pressure of the weld rolls and frequency of the high-frequency current in the induction coil. The purpose of this paper is to develop a 3D model of tube welding process that incorporates realistic material properties and movement of the strip. Design/methodology/approach 3D numerical simulation by the finite element method (FEM) can be used to understand the influence of these process parameters. In this study, the authors have developed a quasi-steady model along with the coupling of electromagnetic and thermal model and incorporation of non-linear electromagnetic and thermal material properties. Findings In this study, 3D FEM model has been established which gives results in accordance with previously published work on induction tube welding. The effect of the Vee-angle and frequency on the temperature profile created in the strip edge during the electromagnetic heating is studied. Practical implications The authors are now able to simulate the induction tube welding process at a more reasonable computational cost enabling an analysis of the process. Originality/value A 3D model has been developed for induction tube welding. A non-linearly coupled system of Maxwell’s electromagnetic equation and the heat equation is implemented using the fixed point iteration method. The model also takes into account non-linear magnetic and thermal material properties. Adaptive remeshing is implemented to optimise mesh size for the electrical skin depth of induced current in the strip. The model also accounts for the high welding-line speeds which influence the mode of heat transfer in the strip.

Experimental investigation of the curing behaviour of fibre composite structures with snap-cure polymer systems

2018 ◽  
Vol 9 (6) ◽  
pp. 768-778
Author(s):  
Rafal Stanik ◽  
Albert Langkamp ◽  
Michael Müller ◽  
Maik Gude ◽  
Anna Boczkowska
Keyword(s):  
Experimental Investigation ◽  
Temperature Field ◽  
Process Parameters ◽  
Material Properties ◽  
Manufacturing Process ◽  
Composite Structures ◽  
Fibre Composite ◽  
Uniform Design ◽  
Curing Process ◽  
Content Type

PurposeNovel snap-cure polymers (SCPs), as matrix systems for high-performance fibre composite materials, provide high potential for manufacturing of component families with small batch sizes and high variability. Especially, the processing of powdered SCP is associated with relatively simple and inexpensive tools. In addition, because of their curing behaviour, they allow short tooling times so that the production of small batch size components is possible in relatively short cycle times. To enable an efficient manufacturing process, an understanding of the curing process is necessary. An adjustment of the process parameters for a uniform design of the temperature field in the material during the manufacturing process is essential. The paper aims to discuss this issue.Design/methodology/approachFor this, a powder SCP resin system was investigated under process-specific conditions. An experimental test approach for determination of various thermal and kinetic material properties was developed. For the adjustment of the process parameters and monitoring of the curing state during the manufacturing process, a kinetic material model was determined. In the end, the validation of the determined model was performed. For this, the temperature distribution under process- specific conditions was measured in order to monitor the curing state of the material.FindingsThe experimental investigation showed an uneven temperature field in the material, which leads to an inhomogeneous curing process. This can lead to residual stresses in the structure, which have a critical impact on the material properties.Originality/valueThe determined kinetic model allows a prediction of the curing reaction and adjustment of the process parameters which is essential, especially for thick-walled components with SCPs.

scholarly journals Electro Magnetic and Heat Conductive FE Analysis on High Frequency Tube Welding Process

2007 ◽  
Vol 93 (5) ◽  
pp. 373-378 ◽  
Author(s):  
Takatoshi OKABE ◽  
Kazuhito KENMOCHI ◽  
Kei SAKATA
Keyword(s):  
High Frequency ◽  
Welding Process ◽  
Fe Analysis ◽  
Tube Welding ◽  
Electro Magnetic

scholarly journals Residual stress detection of welded parts based on excitation vibration response

2020 ◽  
Vol 17 (1) ◽  
pp. 172988142090518
Author(s):  
Xiaohan Liu ◽  
Guangfeng Shi
Keyword(s):  
Residual Stress ◽  
Process Parameters ◽  
High Frequency ◽  
Rapid Development ◽  
Welding Process ◽  
Vibration Signal ◽  
Resonance Analysis ◽  
Orthogonal Parameters ◽  
Set Up ◽  
High Frequency Induction

With the rapid development of the equipment industry, people pay more attention to the stress research of materials. However, there is no more suitable and effective method to detect the variation of residual stress. To find an efficient and useful method to analyze the residual stress of the welded parts, this article selects the Q235 component as the research object and produces a detection robot with the core of processing vibration signal and extracting signal data. In combination with the vibration signal extracted by the robot, we study the influence law of the residual stress of the material through numerical simulation and experimental verification. The detection of residual stress is related to the change in the number of taps of the robot and the increase or decrease in the number of taps of the robot. We used the vibration signal extracted by the robot and analyzed the orthogonal parameters of the high-frequency induction welding process parameters to obtain a set of the most unique process parameters: The tapping angle was 7° and the tapping frequency was 300 Hz. We also set up the robot to extract and analyze the vibration signal using four different hammerheads. The results show that the sub-resonance analysis results as the standard, the deviation of the steel head and the aluminum head hammer is about ±10, the result is more accurate, and the frequency of the nylon and plastic hammer is lower, because it is softer. When the hammer is struck, the contact time of the hammerhead with the workpiece is lengthened, so that a lower frequency can be excited.

Numerical Simulation and Investigation of High Frequency Tube Welding Process

2014 ◽  
Vol 698 ◽  
pp. 245-250 ◽  
Author(s):  
Aleksandr Nikanorov ◽  
Egbert Baake ◽  
Jörg Neumeyer
Keyword(s):  
High Frequency ◽  
Numerical Models ◽  
Thermal Analyses ◽  
Three Dimensional ◽  
Thermal Characteristics ◽  
Welding Process ◽  
Practical Experience ◽  
Time Step ◽  
Tube Welding ◽  
Welding Processes

Welding processes and installations used nowadays are mainly developed on practical experience and analytical calculations. Nevertheless, high frequency induction tube welding is a very complex three-dimensional dynamic process, where the electromagnetic and thermal characteristics are distributed not only in space but in time as well. A more profound detailed investigation of the induction tube welding process can be only done by numerical modeling. Full and local three-dimensional transient numerical models of induction tube welding process with continuous movement of the welded tube have been developed and tested. Coupled electromagnetic and thermal analyses are carried out at each time step of simulation for correction of temperature dependent material properties. Voltage or current of the induction coil can be individually input into electromagnetic analysis at each time step. This approach allows simulating “quasi” steady-state and transient operation modes.

Development of predictive models for effective process parameter selection for single and overlapping laser clad bead geometry

2018 ◽  
Vol 24 (1) ◽  
pp. 214-228 ◽  
Author(s):  
Kush Aggarwal ◽  
R.J. Urbanic ◽  
Syed Mohammad Saqib
Keyword(s):  
Data Collection ◽  
Predictive Model ◽  
Laser Cladding ◽  
Process Planning ◽  
Process Parameters ◽  
Predictive Models ◽  
Goodness Of Fit ◽  
Bead Geometry ◽  
Content Type ◽  
Non Linear

Purpose The purpose of this work is to explore predictive model approaches for selecting laser cladding process settings for a desired bead geometry/overlap strategy. Complementing the modelling challenges is the development of a framework and methodologies to minimize data collection while maximizing the goodness of fit for the predictive models. This is essential for developing a foundation for metallic additive manufacturing process planning solutions. Design/methodology/approach Using the coaxial powder flow laser cladding method, 420 steel cladding powder is deposited on low carbon structural steel plates. A design of experiments (DOE) approach is taken using the response surface methodology (RSM) to establish the experimental configuration. The five process parameters such as laser power, travel speed, etc. are varied to explore their impact on the bead geometry. A total of three replicate experiments are performed and the collected data are assessed using a variety of methods to determine the process trends and the best modelling approaches. Findings There exist unpredictable, non-linear relationships between the process parameters and the bead geometry. The best fit for a predictive model is achieved with the artificial neural network (ANN) approach. Using the RSM, the experimental set is reduced by an order of magnitude; however, a model with R2 = 0.96 is generated with ANN. The predictive model goodness of fit for a single bead is similar to that for the overlapping bead geometry using ANN. Originality/value Developing a bead shape to process parameters model is challenging due to the non-linear coupling between the process parameters and the bead geometry and the number of parameters to be considered. The experimental design and modelling approaches presented in this work illustrate how designed experiments can minimize the data collection and produce a robust predictive model. The output of this work will provide a solid foundation for process planning operations.

Assessment of mechanical properties and flammability of magnesium oxide/PA12 composite material for SLS process

2019 ◽  
Vol 25 (1) ◽  
pp. 176-186 ◽  
Author(s):  
Sunil Kumar Tiwari ◽  
Sarang Pande ◽  
Santosh M. Bobade ◽  
Santosh Kumar
Keyword(s):  
Composite Material ◽  
Composite Materials ◽  
Magnesium Oxide ◽  
Process Parameters ◽  
Material Properties ◽  
Composite Powder ◽  
Flow Index ◽  
Oxide Material ◽  
Content Type ◽  
Material Development

Purpose The purpose of this paper is to propose and develop PA2200-based composite powder containing 0-15 Wt.% magnesium oxide before directly using it in selective laser sintering (SLS) machine to produce end-use products for low-volume production in the engineering applications with keen focus to meet the functional requirements which rely on material properties. Design/methodology/approach The methodology reported emphasises PA2200-based composite powder containing 0-15 Wt.% magnesium oxide development for SLS process which starts with preparation and characterisation of composite material, thermal and rheological study of composite material to decide optimum process parameters for SLS process machine to get optimal part properties. Further, to verify composite material properties, a conventional casting methodology is used. The composition of composite materials those possessing good properties are further selected for processing in SLS process under optimal processing parameters. Findings The process parameters of SLS machine are material-dependent. The effect of temperature in X-ray diffraction profile is negligible in the case of magnesium oxide reinforced PA2200 composite material. The cyclic heating of material increases melting point temperature, this grounds to modify part bed temperature of material every time before processing on SLS machine to uphold build part properties, as well as material. With the rise in temperature, the Melt flow index and rheological property of materials change. The magnesium oxide reinforced PA2200 composite material has high thermal stability than pure PA2200 material. By the addition of small quantity of magnesium oxide, most of the mechanical property and flammability property improves while elongation at break (percentage) decreases significantly. Practical implications The proposed PA2200-based composite powder containing 0-15 Wt.% magnesium oxide material development system and casting metrology to verify developed material properties will be very useful to develop new composite material for SLS process with use of less material. The developed methodology has proven, especially in the case where non-experts or student need to develop composite material for SLS process according to the property requirement of applications. Originality/value Unlike earlier composite material development methodology, the projected methodology of polymer-based composite material and confirmation of material properties instead of commencing SLS process provides straight forward means for SLS process composite materials development with less use of the material and period of time.

Optimization of surface quality and machining time in micro-milling of glass

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ali Dinc ◽  
Ali Mamedov
Keyword(s):  
Surface Quality ◽  
Process Parameters ◽  
Material Properties ◽  
Feed Rate ◽  
Cutting Speed ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Time ◽  
Content Type ◽  
Glass Material

Purpose Glass is a brittle material produced from silica, which has fine material properties, Owing to its sophisticated material properties, glass has found wide application in various high-technological fields such as aviation, aerospace, communication, optics, biomedical and electronics. However, glass is known as difficult to machine material because of its tendency to brittle fracture during machining. This paper aims to investigate the effects of cutting parameters on surface quality and machining time during micro-milling of brittle glass components. Design/methodology/approach A comprehensive genetic algorithm-based optimization strategy is used for selection of process parameters such as cutting speed, feed rate and depth of cut. Effectiveness of the proposed strategy is validated by conducting micro-milling cutting experiments on soda-lime glass material. Findings Results showed that the generated surface quality drastically decrease with increase in the amount of removed material. Lower depth of cut and feed rate result in less amount of cracks formed on machined surface. Also, it is observed that the increase in cutting speed results in better surface quality. Having desired surface quality in shorter machining time directly reduces energy consumed during manufacturing, which is reducing environmental impact of glass parts. Originality/value The novelty of this research work lies in simultaneously considering the effects of cutting speed, feed rate, depth of cut on surface quality and machining time for micro-milling operation of brittle glass material. The model is able to find optimum process parameters for high surface quality and minimum machining time.

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