3D Predictive Model for Controlled Resistance Welding of Composites for Manufacturing Applications

2009 ◽  
Author(s):  
Imad Zammar ◽  
Iraj Mantegh ◽  
Mojtaba Ahmadi
Keyword(s):  
Weld Seam ◽  
Three Dimensional ◽  
Infrared Camera ◽  
Temporal Variations ◽  
Resistance Welding ◽  
Thermoplastic Composites ◽  
Voltage Source ◽  
Transfer Model ◽  
Manufacturing Applications ◽  
Joining Process

A three-dimensional transient heat transfer model is developed for a sequential joining process (resistance welding) applied on thermoplastic composites. This process involves with moving a voltage source along a heating element that conducts the power throughout a resistive mesh, generating heat and melts and bounds two composite surfaces. The model developed here is used to predict the spatial and temporal variations in the current and temperature over the weld seam for different set of input variables. The model integrates both the resistive and thermal behaviours of components involved. The significance of this modeling approach is that it captures the movement of the electrical connection, simulating a sequential joining process along a continuous weld seam. The modeling results are compared with experimental data obtained by thermocouples and infrared camera, and accurately predict the trend of variations in weld temperature.

scholarly journals Computed tomography investigation of the material structure in clinch joints in aluminium fibre-reinforced thermoplastic sheets

2021 ◽  
Author(s):  
Benjamin Gröger ◽  
Daniel Köhler ◽  
Julian Vorderbrüggen ◽  
Juliane Troschitz ◽  
Robert Kupfer ◽  
...  
Keyword(s):  
Computed Tomography ◽  
Three Dimensional ◽  
Material Design ◽  
Material Behavior ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Material Structure ◽  
Research Activities ◽  
Reinforced Thermoplastics ◽  
Joining Process

AbstractRecent developments in automotive and aircraft industry towards a multi-material design pose challenges for modern joining technologies due to different mechanical properties and material compositions of various materials such as composites and metals. Therefore, mechanical joining technologies like clinching are in the focus of current research activities. For multi-material joints of metals and thermoplastic composites thermally assisted clinching processes with advanced tool concepts are well developed. The material-specific properties of fibre-reinforced thermoplastics have a significant influence on the joining process and the resulting material structure in the joining zone. For this reason, it is important to investigate these influences in detail and to understand the phenomena occurring during the joining process. Additionally, this provides the basis for a validation of a numerical simulation of such joining processes. In this paper, the material structure in a joint resulting from a thermally assisted clinching process is investigated. The joining partners are an aluminium sheet and a thermoplastic composite (organo sheet). Using computed tomography enables a three-dimensional investigation that allows a detailed analysis of the phenomena in different joining stages and in the material structure of the finished joint. Consequently, this study provides a more detailed understanding of the material behavior of thermoplastic composites during thermally assisted clinching.

Thermal Modeling for Control of Friction Stir Welding Process in Automated Manufacturing

2011 ◽  
Author(s):  
Iraj Mantegh
Keyword(s):  
Neural Network ◽  
Friction Stir Welding ◽  
Weld Seam ◽  
Control Method ◽  
Thermal Modeling ◽  
Welding Process ◽  
Transfer Model ◽  
Friction Stir ◽  
Friction Stir Welding Process ◽  
Joining Process

Friction stir welding is a patented joining process invented in 1991 at The Welding Institute in Cambridge, UK, and further developed to the stage suitable for production. In this process, a wear resistant rotating tool is used to join sheet and plate with different materials such as aluminum, copper, lead, magnesium, zinc, and titanium. This work studies the thermal characteristics of this process and provides a modeling technique based on Neural Network that can be used for real-time control. A thermal feed-back control method is presented to control the process. Using some thermal modeling for the heat distribution during friction stir welding process, this paper displays the complexity of obtaining an accurate design for the thermal feed back control. A three-dimensional transient heat transfer model is developed here for a sequential joining process (Friction Stir Welding-FSW) applied on aluminum parts. A neural network is created based on a set of experiments to predict the spatial and temporal variations in the temperature over the weld seam for different set of input variables. The model includes the dynamic and friction behavior of the rotating spindle and the thermal behaviors of the weld components involved. The significance of this modeling approach is that it captures the movement of the spindle, simulating a sequential joining process along a continuous weld seam. The modeling results are compared with experimental data obtained by thermocouples and infrared camera, and accurately predict the trend of variations in weld temperature. A fuzzy-logic based controller is proposed to regulate the FSW process parameters to maintain the weld temperature within the margin required to ensure the weld quality. This modeling and control system can have applications in manufacturing aluminum parts in automotive and aerospace industry.

scholarly journals Multi-Objective Optimization of Resistance Welding Process of GF/PP Composites

Polymers ◽  
2021 ◽  
Vol 13 (15) ◽  
pp. 2560
Author(s):  
Guowei Zhang ◽  
Ting Lin ◽  
Ling Luo ◽  
Boming Zhang ◽  
Yuao Qu ◽  
...  
Keyword(s):  
Signal To Noise Ratio ◽  
Welding Process ◽  
Welding Current ◽  
Resistance Welding ◽  
Thermoplastic Composites ◽  
Current Time ◽  
Process Factor ◽  
Welding Equipment ◽  
Lap Shear ◽  
Adhesive Connections

Thermoplastic composites (TPCs) are promising materials for aerospace, transportation, shipbuilding, and civil use owing to their lightweight, rapid prototyping, reprocessing, and environmental recycling advantages. The connection assemblies of TPCs components are crucial to their application; compared with traditional mechanical joints and adhesive connections, fusion connections are more promising, particularly resistance welding. This study aims to investigate the effects of process control parameters, including welding current, time, and pressure, for optimization of resistance welding based on glass fiber-reinforced polypropylene (GF/PP) TPCs and a stainless-steel mesh heating element. A self-designed resistance-welding equipment suitable for the resistance welding process of GF/PP TPCs was manufactured. GF/PP laminates are fabricated using a hot press, and their mechanical properties were evaluated. The resistance distribution of the heating elements was assessed to conform with a normal distribution. Tensile shear experiments were designed and conducted using the Taguchi method to evaluate and predict process factor effects on the lap shear strength (LSS) of GF/PP based on signal-to-noise ratio (S/N) and analysis of variance. The results show that current is the main factor affecting resistance welding quality. The optimal process parameters are a current of 12.5 A, pressure of 2.5 MPa, and time of 540 s. The experimental LSS under the optimized parameters is 12.186 MPa, which has a 6.76% error compared with the result predicted based on the S/N.

scholarly journals A Proof-of-Concept Algorithm for the Retrieval of Total Column Amount of Trace Gases in a Multi-Dimensional Atmosphere

2021 ◽  
Vol 13 (2) ◽  
pp. 270
Author(s):  
Adrian Doicu ◽  
Dmitry S. Efremenko ◽  
Thomas Trautmann
Keyword(s):  
Trace Gases ◽  
Three Dimensional ◽  
Principal Component ◽  
Radiative Transfer Model ◽  
Computational Time ◽  
Transfer Model ◽  
Proof Of Concept ◽  
Discrete Ordinate ◽  
Distribution Method ◽  
Total Column

An algorithm for the retrieval of total column amount of trace gases in a multi-dimensional atmosphere is designed. The algorithm uses (i) certain differential radiance models with internal and external closures as inversion models, (ii) the iteratively regularized Gauss–Newton method as a regularization tool, and (iii) the spherical harmonics discrete ordinate method (SHDOM) as linearized radiative transfer model. For efficiency reasons, SHDOM is equipped with a spectral acceleration approach that combines the correlated k-distribution method with the principal component analysis. The algorithm is used to retrieve the total column amount of nitrogen for two- and three-dimensional cloudy scenes. Although for three-dimensional geometries, the computational time is high, the main concepts of the algorithm are correct and the retrieval results are accurate.

Flow Past a Spinning Sphere With Surface Blowing and Heat Transfer

2005 ◽  
Vol 127 (1) ◽  
pp. 163-171 ◽  
Author(s):  
H. Niazmand ◽  
M. Renksizbulut
Keyword(s):  
Heat Transfer ◽  
Three Dimensional ◽  
Flow Regimes ◽  
Solid Sphere ◽  
Temporal Variations ◽  
Transfer Coefficients ◽  
Transfer Rates ◽  
Particle Spin ◽  
Flow Past ◽  
Angular Velocities

Computations are performed to determine the transient three-dimensional heat transfer rates and fluid forces acting on a stream-wise spinning sphere for Reynolds numbers in the range 10⩽Re⩽300 and angular velocities Ωx⩽2. In this Re range, classical flow past a solid sphere develops four different flow regimes, and the effects of particle spin are studied in each regime. Furthermore, the combined effects of particle spin and surface blowing are examined. Sphere spin increases drag in all flow regimes, while lift shows a nonmonotonic behavior. Heat transfer rates are not influenced by spin up to a certain Ωx but increase monotonically thereafter. An interesting feature associated with sphere spin is the development of a special wake regime such that the wake simply spins without temporal variations in its shape. For this flow condition, the magnitudes of the lift, drag, and heat transfer coefficients remain constant in time. Correlations are provided for drag and heat transfer.

Fatigue Crack Growth at Electrical Resistance Welding Seam of API 5L X-70 Steel Line Pipe at Varied Orientations

2017 ◽  
Vol 139 (3) ◽  
Author(s):  
Craig Taylor ◽  
Sreekanta Das ◽  
Laurie Collins ◽  
Muhammad Rashid
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Base Metal ◽  
Electrical Resistance ◽  
Weld Seam ◽  
Full Scale ◽  
Resistance Welding ◽  
Line Pipe ◽  
Full Scale Testing

Very few studies have been conducted concerning fatigue in steel line pipe and fewer using full-scale testing. Further, at the time of this study, no research on full-scale testing was available in open literature regarding fatigue behavior of line pipe with longitudinal cracks, despite being considered more critical than the line pipe with cracks oriented in the circumferential direction. In the current research work, fatigue crack growth was investigated in NPS 20, API 5L X-70 grade, electrical resistance welding (ERW) straight-seam steel line pipes in the base metal and at the weld seam for various orientations. It was found that there was no significant difference between fatigue crack growth in the base metal and at the weld seam for the tested stress ratio. Increasing the angle of inclination of the crack with respect to the weld line was found to decrease the rate of fatigue crack growth due to a decrease in the mode I stress component. Finally, it was observed that despite the difference in fatigue crack growth rates, the crack aspect ratios were nearly identical for all cracks at the same crack depth.

Transient Three-Dimensional Heat Transfer Model of a Solar Thermochemical Reactor for H2O and CO2 Splitting via Nonstoichiometric Ceria Redox Cycling

2013 ◽  
Author(s):  
Justin Lapp ◽  
Wojciech Lipiński
Keyword(s):  
Heat Transfer ◽  
Heat Recovery ◽  
Fuel Efficiency ◽  
Three Dimensional ◽  
Reactor Design ◽  
Heat Transfer Model ◽  
Heat Fluxes ◽  
Transfer Model ◽  
Rotating Cylinders ◽  
Solar Receiver

A transient heat transfer model is developed for a solar reactor prototype for H2O and CO2 splitting via two-step non-stoichiometric ceria cycling. Counter-rotating cylinders of reactive and inert materials cycling between high and low temperature zones permit continuous operation and heat recovery. To guide the reactor design a transient three-dimensional heat transfer model is developed based on transient energy conservation, accounting for conduction, convection, radiation, and chemical reactions. The model domain includes the rotating cylinders, a solar receiver cavity, and insulated reactor body. Radiative heat transfer is analyzed using a combination of the Monte Carlo method, Rosseland diffusion approximation, and the net radiation method. Quasi-steady state distributions of temperatures, heat fluxes, and the non-stoichiometric coefficient are reported. Ceria cycles between temperatures of 1708 K and 1376 K. A heat recovery effectiveness of 28% and solar-to-fuel efficiency of 5.2% are predicted for an unoptimized reactor design.

scholarly journals Accelerated RAPID Model Using Heterogeneous Porous Objects

2018 ◽  
Vol 10 (8) ◽  
pp. 1264 ◽  
Author(s):  
Huaguo Huang
Keyword(s):  
Three Dimensional ◽  
Computation Time ◽  
Single Scattering ◽  
Projection Algorithm ◽  
Forest Plot ◽  
Transfer Model ◽  
Bidirectional Reflectance Factor ◽  
Reflectance Factor ◽  
Radiation Transfer Model ◽  
Porous Object

To enhance the capability of three-dimensional (3D) radiative transfer models at the kilometer scale (km-scale), the radiosity applicable to porous individual objects (RAPID) model has been upgraded to RAPID3. The major innovation is that the homogeneous porous object concept (HOMOBJ) used for a tree crown scale is extended to a heterogeneous porous object (HETOBJ) for a forest plot scale. Correspondingly, the radiosity-graphics-combined method has been extended from HOMOBJ to HETOBJ, including the random dynamic projection algorithm, the updated modules of view factors, the single scattering estimation, the multiple scattering solutions, and the bidirectional reflectance factor (BRF) calculations. Five cases of the third radiation transfer model intercomparison (RAMI-3) have been used to verify RAPID3 by the RAMI-3 online checker. Seven scenes with different degrees of topography (valleys and hills) at 500 m size have also been simulated. Using a personal computer (CPU 2.5 GHz, memory 4 GB), the computation time of BRF at 500 m is only approximately 13 min per scene. The mean root mean square error is 0.015. RAPID3 simulated the enhanced contrast of BRF between backward and forward directions due to topography. RAPID3 has been integrated into the free RAPID platform, which should be very useful for the remote sensing community. In addition, the HETOBJ concept may also be useful for the speedup of ray tracing models.

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