Demonstration of Intelligent Welding Machine for Polyethylene Pipe

2021 ◽  
Author(s):  
Guangte Xiang ◽  
Yurui Hu ◽  
Sheng Zeng ◽  
Jianfeng Shi ◽  
Jinyang Zheng
Keyword(s):  
Welding Process ◽  
Maximum Temperature ◽  
Welding Parameters ◽  
Welding Time ◽  
Constant Voltage ◽  
Welding Machine ◽  
Reinforced Composite ◽  
Composite Pipe ◽  
The Difference

Abstract Electrofusion (EF) welding is one of the most common connection methods for polyethylene (PE) pipe, as well as thermoplastic pipe and reinforced composite pipe. Conventional EF welding generally adopts constant-voltage welding mode. The welding machine outputs a constant welding voltage to heat the resistance wire within specific welding time. In our previous study, intelligent welding machine was designed to ensure the quality of the EF joint, based on the study of the temperature field in EF joint. In this paper, three experiments were used to show the difference between the intelligent welding machine and traditional welding machine. The intelligent welding machine can actively adjust the welding parameters to ensure the quality of EF joint even it was given the wrong welding voltage and welding time. Compared with the traditional welding machine, the intelligent welding machine can automatically control the maximum temperature and the depth of melting region in EF joint during the welding process, and this method applies for EF joints with various diameters or design welding parameters.

A Simulation of Spot Welding Process

2014 ◽  
Vol 657 ◽  
pp. 226-230 ◽  
Author(s):  
Viorel Cohal
Keyword(s):  
Process Parameters ◽  
Growth Curve ◽  
Spot Welding ◽  
Welding Process ◽  
Process Parameter ◽  
Welding Parameters ◽  
Welding Machine

The paper presents the optimization of spot welding parameters using offline simulation. The procedure of making simulation with SORPAS® is similar to the procedure of doing practical welding process, which can be divided into the following three steps:Data preparation - the materials and geometries of the workpieces and electrodes are defined, the type of welding machine is selected and the process parameters are specified.Running simulation of welding - the parts are welded in the selected welding machine with the specified process parameter settings. The simulations can be carried out in four ways: single simulations, batch simulations, automated optimizations and weld planning.Evaluation of results - the results of welding and quality of weld are evaluated thus the design and parameter settings are verified. With the optimization procedures the weld growth curve can be obtained.

scholarly journals Influence of Welding Parameters On Grain Size, Haz and Degree of Dilution in 6063-t5 Alloy. Optimisation Through the Taguchi Method of the Gmaw Welding Process.

2022 ◽  
Author(s):  
Jose Luis Meseguer Valdenebro ◽  
Eusebio José Martínez Conesa ◽  
Antonio Portoles
Keyword(s):  
Grain Size ◽  
Taguchi Method ◽  
Heat Affected Zone ◽  
Welding Process ◽  
Welding Parameter ◽  
Welding Parameters ◽  
Taguchi’S Method ◽  
Gmaw Welding ◽  
Made In

Abstract The aim of this work is to carry out the design of experiments that determine the influence of the welding parameters using Taguchi’s method on the grain size, HAZ, and the degree of dilution in 6063-T5 alloy. The welding process used is GMAW and the welding parameters are power, welding speed and bevel spacing. The study of the influence of the welding parameters on the measurements made in the welding (which are the size of heat affected zone, the degree of dilution, and the grain size) allows one to determine the quality of the joint . In addition, the welding parameter most influential in minimising the three measurements will be determined.

scholarly journals Numerical Simulation Mode of Spot Contact Welding Processes

2021 ◽  
pp. 85-91
Author(s):  
А.С. Угловский ◽  
И.М. Соцкая ◽  
Е.В. Шешунова
Keyword(s):  
Spot Welding ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Welding Parameters ◽  
Low Carbon ◽  
Detailed Data ◽  
Welding Quality ◽  
Welding Processes ◽  
Contact Welding

Цель рассмотрения численного метода заключалась в получении подробных данных, позволяющих оценить проведение сварочного процесса: изменение объёма сварного шва, радиуса сварного шва, радиуса зоны термического влияния. При проведении моделирования авторами выведены зависимости параметров точечной сварки низкоуглеродистой стали толщиной до 3,2 мм. Данные зависимости будут определять качество сварных швов. Соответствующее сочетание параметров точечной сварки обеспечит прочное соединение и хорошее качество сварки. The purpose of the numerical method consideration was to obtain detailed data allowing evaluating the performance of the welding process: changing the volume of the weld, the radius of the weld, the radius of the weld-affected zone. During the simulation the authors have derived dependencies of the parameters of spot welding of low-carbon steel up to 3.2 mm thick. These dependencies will determine the quality of the welds. The correct combination of spot welding parameters will ensure a firm joint and good welding quality.

scholarly journals Preliminary Research on Influence of Welding Parameters Strength at Welded Joints in Ribbed Reinforcing Steel

2020 ◽  
Vol 14 (3) ◽  
pp. 369-374
Author(s):  
Željko Bilić ◽  
Ivan Samardžić ◽  
Nedjeljko Mišina ◽  
Katarina Stoić
Keyword(s):  
Welded Joint ◽  
Welding Process ◽  
Welding Parameters ◽  
Non Destructive Testing ◽  
Destructive Testing ◽  
Butt Welding ◽  
Control Interface ◽  
High Level ◽  
Non Destructive

As already known, no proper control or process control parameter which absolutely guarantees a high level quality of joints made by electro-resistive welding has been established so far, especially when all possible parameters are taken into account during the welding process. Due to the process of butt-welding being very short-lived, ensuring quality of the joints is a difficult and under-researched problem. The application of non-destructive testing methods to the control interface joints is also not reliable. Therefore, further research in this area should concentrate on studying the influence of basic welding parameters, and calculating their direct or indirect impact can serve to achieve a highquality welded joint with for practice sufficient accuracy.

An Effective Approach Based on Response Surface Methodology for Predicting Friction Welding Parameters

2016 ◽  
Vol 35 (3) ◽  
pp. 235-241
Author(s):  
Sare Celik ◽  
Aslan Deniz Karaoglan ◽  
Ismail Ersozlu
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Friction Welding ◽  
Welding Process ◽  
Raw Material ◽  
Maximum Temperature ◽  
Welding Parameters ◽  
Rotating Speed ◽  
Minimum Number ◽  
Normal Carbon

AbstractThe joining of dissimilar metals is one of the most essential necessities of industries. Manufacturing by the joint of alloy steel and normal carbon steel is used in production, because it decreases raw material cost. The friction welding process parameters such as friction pressure, friction time, upset pressure, upset time and rotating speed play the major roles in determining the strength and microstructure of the joints. In this study, response surface methodology (RSM), which is a well-known design of experiments approach, is used for modeling the mathematical relation between the responses (tensile strength and maximum temperature), and the friction welding parameters with minimum number of experiments. The results show that RSM is an effective method for this type of problems for developing models and prediction.

Optimizing spot welding parameters in a sheet metal assembly by neural networks and genetic algorithm

2007 ◽  
Vol 221 (7) ◽  
pp. 1175-1184 ◽  
Author(s):  
M Hamedi ◽  
M Shariatpanahi ◽  
A Mansourzadeh
Keyword(s):  
Neural Networks ◽  
Spot Welding ◽  
Welding Process ◽  
Welding Current ◽  
The Body ◽  
Welding Parameters ◽  
Automotive Body ◽  
Body In White ◽  
Assembly Operations

Deformation of the spot-welded sub-assemblies in assembly operations and the gap between the matching sub-assemblies have been quality concerns specifically in the automotive industry. Overall quality of the car body and its sub-assemblies, apart from quality of each stamped part, depends markedly on the welding process. This paper considers optimization of three important process parameters in the spot welding of the body components, namely welding current, welding time, and gun force. In this research, first the effects of these parameters on deformation of the sub-assemblies are experimentally investigated. Then neural networks and multi-objective genetic algorithms are utilized to select the optimum values of welding parameters that yield the least values of dimensional deviations in the sub-assemblies. Welding sub-assemblies with the optimized set of parameters brought all of them into the tolerance range. The proposed approach can be utilized in manufacturing sub-assemblies that can fit and match better with adjacent parts in the automotive body. It enhances quality of the joint and will result in improving overall quality of the body in white.

Using of Welding Virtual Numerical Simulation as the Technical Support for Industry

2016 ◽  
Vol 1138 ◽  
pp. 49-55
Author(s):  
Marek Slováček ◽  
Josef Tejc ◽  
Mojmír Vaněk
Keyword(s):  
Numerical Simulation ◽  
Numerical Simulations ◽  
Welded Joints ◽  
Welding Process ◽  
Austenitic Steels ◽  
Welding Parameters ◽  
Efficient Production ◽  
Weld Joints ◽  
Mechanical Properties Prediction

Welding as a modern, highly efficient production technology found its position in almost all industries. At the same time the demands on the quality of the welded joints have been constantly growing in all production areas. Great demand on the quality of the welded joints consequently causes more experimental or prototype – so called – validation joints that take place before the welding of final construction. These experiments, prototypes aim at – for instance – defining the appropriate welding technology, material, pre-heating, welding parameters, clamping condition and optimizing the welding process. Naturally, these experiments and prototypes make production more expensive. Numerical simulations of welding – in the area of production preparation as well as of production proper – have been frequently used recently. Numerical simulations supported by experimental measurements can simulate the actual welding process very close to reality. The new material models for hardness and mechanical properties prediction based on numerical simulation solution will be introduced.The paper covers some typical welding cases from energy industrial sector. The homogenous and heterogeneous weld joints from modern energy Cr-Mo-Ni-V steels (including modern austenitic steels) were done as prototype welding. The numerical simulation of these weld joints including post weld heat treatment process were done and welding technologies were optimised based on the numerical simulation results. The calculated hardness was compared with real measurements. During project the complete material properties which are needed for numerical simulation were measured. Simplify numerical lifetime prediction of weld joints including results from numerical welding analyse (as residual stresses and plastic deformation) were done.

Experimental and numerical investigation of the characteristics of flash-butt joints used in continuously welded rails

2019 ◽  
Vol 234 (1) ◽  
pp. 65-79 ◽  
Author(s):  
Mohsen Ghazanfari ◽  
Parisa Hosseini Tehrani
Keyword(s):  
Heat Affected Zone ◽  
Experimental Studies ◽  
Welding Process ◽  
Material Model ◽  
Maximum Temperature ◽  
Hardness Profile ◽  
Railway Network ◽  
Butt Welding ◽  
Influence Of Temperature On

Continuously welded rails are widely used in the Iran railway network, which are generally built using the flash-butt welding process. To accurately model the flash-butt welding process, thermal analysis, and prediction of the welding residual stresses, the influence of upsetting force on the total electrical resistance and a material model with consideration of the influence of temperature on the material properties are included in the numerical modeling. In this paper, numerical and experimental studies, including the finite element method, thermography, metallography, and hardness testing are performed to determine the characteristics of the welded UIC60 rail. By studying the fractured flash-butt welded UIC60 rails, it is shown that the location of the crack initiation and the rail failure in the web and heat affected zone of the welded rails was similar as compared to the maximum tensile residual stress calculated by numerical simulation. According to the numerical and experimental results, it is shown that four key parameters – such as the maximum temperature during the welding process, the total welding time, the upsetting time, and the upsetting force – control the size, microstructure, and the hardness profile of the heat affected zone which directly affects the characteristics and quality of welding.

Investigation of the Weldability of the Self-Reinforced Polypropylene Composites

2010 ◽  
Vol 659 ◽  
pp. 25-30 ◽  
Author(s):  
Zoltán Kiss ◽  
Ákos Kmetty ◽  
Tamás Bárány
Keyword(s):  
Ultrasonic Welding ◽  
The Self ◽  
Holding Time ◽  
Welding Parameters ◽  
Polypropylene Composites ◽  
Welding Machine ◽  
Reinforced Composite ◽  
Different Thickness

In the present work the weldability of self-reinforced composite was investigated. As reinforcement a fabric, woven from highly stretched split PP yarns, whereas as matrix materials of two kinds of random polypropylene copolymer (with ethylene) were used. The composite sheets were produced by film-stacking method and compression molded with different thickness (1 mm, 2 mm) with different contents at different processing temperatures keeping the holding time and pressure constant. The SRPPC sheets were welded by ultrasonic welding machine with different welding parameters. The welds were qualified by mechanical and microscopic tests. The results showed that the thermoplastic reinforcement has not got melted; therefore the reinforcement was kept the strength-increasing effect.

scholarly journals Representation of gas metal arc pulsed welding process behavior on bead geometry: a study of leading variables

2021 ◽  
Vol 2139 (1) ◽  
pp. 012008
Author(s):  
J L Lázaro Plata ◽  
C S Sánchez Rincón
Keyword(s):  
Welding Process ◽  
Weld Bead ◽  
Structural Quality ◽  
Welding Parameters ◽  
Bead Geometry ◽  
Automatic Welding ◽  
Cored Wire ◽  
Experimental Development ◽  
Welding Processes

Abstract Gas metal arc welding is one of the most influential processes in the production and repair of structures and equipment; therefore, the need to improve the productivity and quality of welded joints has led to the development of techniques for good control of welding parameters. Also, the development of semi-automatic welding processes led to the control of one of the variables such as pulsed current; this technique is characterized by a lower heat input and lower energy expenditure, which directly influences the structural quality of the welded joint and the geometry of the weld bead. This work focused on evaluating the effects of various welding operating parameters using the central composite design tool based on the response surface methodology; next, the experimental development employed an inverter type power source for weld depositions, a commercial grade Stargold clean 96% Ar and 4% CO2 shielding gas at the rate of 15 L/min stationary arc, a 1.2 mm metal cored wire for welding deposit and a carbon steel base plate with a thickness of 6 mm. During the welding process, the torch was kept at a 90° inclination and a 16 mm stroke. To examine the adequacy of the empirical models and the significance of the regression coefficients, the variance analysis was employed. Consequently, the graphs were obtained through the determination of the model; from the statistical results obtained, it was shown that the above models were adequate to predict the weld width, bead height, and penetration within the range of variables studied. Furthermore, it was observed that the wire feed rate it has a very marked effect on weld bead geometry, followed by frequency pulse and peak current; finally, the effectiveness of employing these methodologies for the management of variables attributing to the execution of welding tasks with higher accuracy was demonstrated.

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