scholarly journals Computing Welding Distortion: Comparison of Different Industrially Applicable Methods

2005 ◽  
Vol 6-8 ◽  
pp. 195-202 ◽  
Author(s):  
D. Tikhomirov ◽  
Bert Rietman ◽  
K. Kose ◽  
M. Makkink
Keyword(s):  
Numerical Simulation ◽  
Development Stage ◽  
Welding Distortion ◽  
Welding Parameters ◽  
Automotive Part ◽  
Virtual Product

Welding distortion is one of the major concerns of the industrial joining practice. In order to obtain optimal welding parameters many experiments have to be carried out. Numerical simulation enables a virtual examination of the welding distortion without performing expensive experiments. In this contribution some industrially applicable methods of weld modeling are discussed. They enable the fast distortion assessment in the pre-development stage. The application of these methods on a complex automotive part is conducted followed by a comparison of computed distortion with measured values. Furthermore, aspects of integration of weld modeling into the virtual product chain are addressed.

Prognostic criteria for Polar Lows

2021 ◽  
Author(s):  
Natalia Vazaeva ◽  
Otto Chkhetiani ◽  
Michael Kurgansky
Keyword(s):  
Numerical Simulation ◽  
Wind Velocity ◽  
Large Scale ◽  
Satellite Image ◽  
Development Stage ◽  
Mature Stage ◽  
Initial Development ◽  
Polar Lows ◽  
Prognostic Criteria ◽  
Main Challenge

<p>Polar lows (PLs) are important mesoscale (horizontal diameter up to 1000 km) maritime weather systems at high latitudes, forming pole ward from the polar front. We consider the possible prognostic criteria of PLs, in particular, the kinematic helicity as a quadratic characteristic related to the integral vortex formations and the kinematic vorticity number (KVN). To calculate such characteristics we use reanalysis data and the results of numerical simulation with the WRF-ARW model (Version 4.1.) for the PLs over the Nordic (Norwegian and Barents) seas. For comparison, experimental data are used.</p><p>Our estimate of helicity is based on the connection of an integral helicity (IH) in the Ekman layer with the geostrophic wind velocity, due to the good correlation between IH and half the sum of the wind velocity squared. We have chosen IH averaged over preselected area covering the locality of PLs genesis. This area was moving along with the centre of PL during the numerical simulation.</p><p>The genesis of PLs can be divided into three stages: (i) an initial development stage, in which a number of small vortices appear in a shear zone; (ii) a late development stage, characterized by the merger of vortices; (iii) a mature stage, in which only a single PL is present. Approximately one day before PL formation, a significant increase in helicity was observed. The average helicity bulk density of large-scale motions has values of 0.3 – 0.4 ms<sup>-2</sup>. The local changes in helicity are adjacent to the front side of the PLs. The IH criterion described facilitates the identification of the PLs genesis area. For a more detailed analysis of the PL genesis, it is recommended to apply KVN, which is the additional indicator of PL size and intensity. At the moment of maximum intensity of PLs KVN can reach values of 12 – 14 units. The advantage of using KVN is also in its clear change directly in the centre of the emerging PLs, which allows to precisely indicates the limits of the most intense part of PLs.</p><p>The main challenge is to make the operational forecast of PLs possible through the selection of the prognostic integral characteristics of PLs, sufficient for PLs identification and for analysis of their size and intensity in a convenient, usable and understandable way. The criteria associated with vorticity and helicity are reflected in the PLs genesis and development quite clearly. At this time, such a claim is only a hypothesis, which must be tested using a larger set of cases. Future work will need to extend these analyses to other active PL basins. Also, it would be interesting to compare the representation of PLs by using any other criteria. It is intended to use our combined criteria as a precursor to machine learning-based PLs identification procedure where satellite image analysis and capture of particular cloud patterns are currently applied in most of the cases. It would eliminate the time consuming first stage of collecting data sets.</p><p>This work was supported by the Russian Science Foundation (project No. 19-17-00248).</p>

Deformation Analysis for Welding Assembly Processes of Automobile Panels

2010 ◽  
Vol 118-120 ◽  
pp. 70-74
Author(s):  
Yu Liu ◽  
Jian Xin Liu ◽  
Shu Yi Yan ◽  
Zhi Min Wang ◽  
Bing Zhang
Keyword(s):  
Numerical Simulation ◽  
Welding Process ◽  
Coupling Method ◽  
Welding Distortion ◽  
Deformation Analysis ◽  
Assembly Quality ◽  
Automobile Body ◽  
Dimensional Deviation ◽  
Assembly Deviation

Welding process of automobile panels is a key process in the manufacturing of automobile body and its quality directly impact on the appearance and quality of automobile. The causes of dimensional deviation of welded assembly could be workpieces variation, assembly tooling variation, and welding distortion. As a major source of assembly deviation, dimensional variations of workpieces have important effects on the assembly quality of automobile body. In this paper, pre-stressing was used to reflect the workpieces’ variation and the node coupling method was used in the numerical simulation to predict the deformation of assembly caused by the welding process of automobile panels. And further the computation results were listed and compared with the measured ones.

Material characterization for numerical simulation of manufacturing of automotive part made of magnesium alloy

2019 ◽  
Vol 20 (1) ◽  
Author(s):  
Maciej Pietrzyk ◽  
Roman Kuziak ◽  
Krzysztof Bzowski ◽  
Łukasz Rauch ◽  
Mateusz Ambroziński ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Magnesium Alloy ◽  
Material Characterization ◽  
Automotive Part

scholarly journals Steel Sheets Laser Lap Joint Welding—Process Analysis

Materials ◽  
2020 ◽  
Vol 13 (10) ◽  
pp. 2258 ◽  
Author(s):  
Hubert Danielewski ◽  
Andrzej Skrzypczyk
Keyword(s):  
Numerical Simulation ◽  
Laser Beam ◽  
Steel Sheet ◽  
Process Analysis ◽  
Welding Process ◽  
Parameters Estimation ◽  
Welding Parameters ◽  
Lap Joint ◽  
Beam Radiation ◽  
Keyhole Effect

This article presents the results of steel-sheet lap-joint-welding using laser beam radiation. The use of a laser beam and keyhole effect for deep material penetration in lap joint welding was presented. Thermodynamic mechanism of laser welding is related to material properties and process parameters. Estimation of welding parameters and joint properties’ analysis was performed through numerical simulation. The article presents a possibility of modeling laser lap-joint welding by using Simufact Welding software based on Marc solver and thermo-mechanical solution. Numerical calculation was performed for surface and conical volumetric heat sources simulating laser absorption and keyhole effect during steel sheet welding. Thermo-mechanical results of fusion zone (FZ), heat-affected zone (HAZ) and phase transformations calculated in numerical simulation were analyzed. The welding parameters for partial sealed joint penetration dedicated for gas piping installations were estimated from the numerical analysis. Low-carbon constructional steel was used for numerical and experimental analyses. A trial joint based on the estimated parameters was prepared by using a CO2 laser. Numerical and experimental results in the form of hardness distributions and weld geometry were compared. Metallographic analysis of the obtained weld was presented, including crystallographic structures and inclusions in the cross section of the joint.

An Automated Optimization Process for a CAE Driven Product Development

2003 ◽  
Vol 125 (4) ◽  
pp. 694-700 ◽  
Author(s):  
M. Merkel ◽  
A. Schumacher
Keyword(s):  
Product Development ◽  
Physical Phenomenon ◽  
Fundamental Issue ◽  
Software Products ◽  
Automotive Part ◽  
Cae Analysis ◽  
Virtual Product Development ◽  
Automated Optimization ◽  
Optimization Loop ◽  
Virtual Product

Within the product development the need for generating design variants is given in many situations, for example to optimize an existing initial design with respect to new or modified requirements. For an efficient process it is essential that these variations can be done very easily within a small timeframe. In the virtual product development the physical characteristic of a component is determined by numerical simulation. Commercial software products exist for nearly each physical phenomenon. Often these methods are covered under CAE. A fundamental issue for building and analyzing variants easily and fast is a seamless interaction between the CAD and CAE software tools. This paper presents a powerful CAD/CAE sequence to the engineer’s community, where in contrast to other approaches results of the CAE analysis directly interact with CAD data. This strategy is supported by describing the product’s geometry by parameters. The CAD/CAE sequence is integrated in an optimization loop. The presented application example is an automotive part.

Genesis and Development Mechanisms of a Polar Mesocyclone over the Japan Sea

2014 ◽  
Vol 142 (6) ◽  
pp. 2248-2270 ◽  
Author(s):  
Shun-ichi I. Watanabe ◽  
Hiroshi Niino
Keyword(s):  
Numerical Simulation ◽  
Life Cycle ◽  
Shear Zone ◽  
Latent Heat ◽  
Japan Sea ◽  
Development Stage ◽  
Heat Fluxes ◽  
Mature Stage ◽  
Late Development ◽  
The Japan Sea

Abstract A polar mesocyclone (PMC) observed over the Japan Sea on 30 December 2010 was studied using a nonhydrostatic mesoscale numerical model with a horizontal resolution of 2 km. The numerical simulation successfully reproduced the observed life cycle of the PMC. The results of the numerical simulation suggest that the life cycle of the PMC may be divided into three stages: an early development stage, in which a number of small vortices appear in a shear zone; a late development stage, which is characterized by the merger of vortices and the formation of a few larger vortices; and a mature stage, in which only a single PMC is present. During the early development stage, vortices are generated in the shear zones of strong updrafts in discrete cumulus convection cells. In contrast, during the late development stage, the vortices develop as a result of barotropic instability in the shear zone. A cloud-free eye and spiral cloud bands accompany the mature stage of a simulated PMC. A warm core structure also forms at the center of the PMC on account of adiabatic warming associated with downdrafts. The structures in the PMC during the mature stage resemble those of a tropical cyclone. Sensitivity experiments, in which sensible and latent heat fluxes from the sea surface and condensational heating were switched on/off, demonstrate that condensational heating is critical to the development of the PMC at all stages, and that sensible and latent heat fluxes play secondary roles.

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.

Numerical Simulation of Welding Distortion Using Shrinkage Force Approach and Application

2010 ◽  
Vol 129-131 ◽  
pp. 867-871 ◽  
Author(s):  
Yao Hui Lu ◽  
Ping Bo Wu ◽  
Jing Zeng ◽  
Xing Wen Wu
Keyword(s):  
Numerical Simulation ◽  
Welding Distortion ◽  
Railway Vehicle ◽  
Welding Deformation ◽  
Element Analysis ◽  
Force Method ◽  
The Finite Element Analysis ◽  
Numerical Simulation Methods ◽  
Shrinkage Force

The control of welding distortion during assembling process is very important. Using numerical simulation methods to obtain the welding distortion is an effective way to control the quality of welding. At first, taking the bead-on-plate welding as an example, the predictions of welding distortion were made using the shrinkage force method and the thermo-elastic-plastic method for comparison. It was concluded from the comparison that the simulation results by using the two methods are consistent. Therefore, the shrinkage force method can be applied to prediction of structural welding distortion in engineering. Based on the theory of welding shrinking force, welding deformation was predicted for the bogie side frame of railway vehicle. According to all the deformation results from the finite element analysis, the welding deformation of the bogie side frame was lager than the tolerance of quality and in reasonable agreement with the experimentally determined distortion values from literature. The work in this paper indicated that the shrinkage force method was effective to predict the welding deformation and to control the welding quality in large complex structures, such as the bogie frame of railway vehicle.

Virtual Product Development and Reliability Design of Camera Cover

2011 ◽  
Vol 460-461 ◽  
pp. 40-43
Author(s):  
Wei Hua Kuang ◽  
Li Si Chen
Keyword(s):  
Numerical Simulation ◽  
Optimal Design ◽  
Injection Molding ◽  
Product Development ◽  
Reliability Design ◽  
Gate Location ◽  
Injection Process ◽  
Cad Cam ◽  
Virtual Product Development ◽  
Virtual Product

The paper finished the design of injection molding by UG MoldWizard module, and realized numerical simulation and analysis of injection process by MoldFlow software. Best gate location was obtained. Fill time was deeply studied. Though the mold designing process, it completed the CAD/CAM/CAE integration of the injection molding, and achieved the optimal design of the mold. NC machining of the mold core was programmed by UG NX software. CAD/CAM/CAE greatly improved the development efficient of the mold.

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