Abstract: Resistance spot welding (RSW) has been used widely to join sheet metals. It has been a challenge to get required weld quality in spot welding of dissimilar thickness materials. Weld parameters are not generally available in standards for thickness beyond 4mm. This paper presents the welding process design and parameter optimization of RSW used in joining of low carbon steel sheet of thickness 0.8 mm and metal strips of cross section 10 x 5mm for electrical motor applications. Taguchi quality design was adopted for weld current and time optimization using L9 orthogonal array. Optimum process parameters (current- 3.5kA and time- 10 cycles) were obtained from the Taguchi analysis and shear test results. Confirmation experiment result revealed that the weld quality was within acceptable interval. Further, numerical simulation of RSW process was carried out with selected weld parameters to quantify the temperature at faying surface and check for formation of appropriate nugget. The nugget geometry measured after peel test and predicted from numerical validation method were similar and in accordance with the standards.
Abstract: The numerical simulation of the crack welding process is reported in this paper. The thermo-electro-structural coupled-field finite element analysis is adopted to investigate the welding process of crack surfaces. In the simulation, the pressure-dependent and temperature-dependent electrical contact conditions are considered. From the results, the crack surfaces can melt and weld together under the compressive load and electric current. The contact pressure effect must be considered in the finite element analysis to obtain more practical results.
Abstract: Tungsten Inert Gas (TIG) welding is a high quality welding process used to weld the thin metals and their alloy. 5083 Aluminium alloys play an important role in engineering and metallurgy field because of excellent corrosion properties, ease of fabrication and high specific strength coupled with best combination of toughness and formability.
TIG welding technique is one of the precise and fastest processes used in aerospace, ship and marine industries. TIG welding process is used to analyze the data and evaluate the influence of input parameters on tensile strength of 5083 Al-alloy specimens with dimensions of 100mm long x 15mm wide x 5mm thick. Welding current (I), gas flow rate (G) and welding speed (S) are the input parameters which effect tensile strength of 5083 Al-alloy welded joints. As welding speed increased, tensile strength increases first till optimum value and after that both decreases by increasing welding speed further. Results of the study show that maximum tensile strength of 129 MPa of weld joint are obtained at welding current of 240 Amps, gas flow rate of 7 Lt/min and welding speed of 98 mm/min. These values are the optimum values of input parameters which help to produce efficient weld joint that have good mechanical properties as a tensile strength.
Abstract: This paper summarizes and presents main results of an in-depth numerical analysis dealing with the shear buckling resistance of aluminum plate girders. The studies conducted have permitted the development of a simple design expression to determine the critical shear buckling stress in aluminum web panels. This expression takes into account the effects of reduction of strength in aluminum alloys due to welding process. Ultimate shear resistance (USR) of plate girders can be obtained theoretically using Cardiff theory or Hӧglund’s theory. USR of aluminum alloy plate girders predicted theoretically using BS8118 appear inconsistent when compared with test data. Theoretical predictions based on Hӧglund’s theory, are more realistic. Cardiff theory proposed to predict the USR of steel plate girders only. Welded aluminum alloy plate girders studied experimentally by others; the USR resulted from tests are reviewed. Comparison between the test results with the values obtained from Hӧglund’s theory, BS8118 design method and Cardiff theory performed theoretically. Finally, a new equation based on Cardiff tension-field theory, proposed to predict theoretically the USR of aluminum plate girders.
Abstract: Experimental study was conducted to assess personal welding fumes exposure toward welders during an aluminum metal inert gas (MIG) process. The welding process was carried out by a welding machine attached to a Computer Numerical Control (CNC) workbench. A dummy welder was used to replicate welder during welding works and was attached with sampling pumps and filter cassettes for welding fumes sampling. Direct reading instruments to measure air velocity, humidity, temperature and particulate matter with diameter size 10µm or less (PM10) were located behind the dummy welder and parallel to the neck collar level to make sure the measured welding fumes exposure were not being influenced by other factors. Welding fumes exposure during standing and sitting position with and without the usage of local exhaust ventilation (LEV) was investigated. Welding fume samples were then digested and analyzed by using inductively coupled plasma mass spectroscopy (ICP-MS) according to ASTM D7439-08 method. The results of the study showed the welding fume exposure during sitting was lower compared to standing position. LEV helped reduce aluminum and lead exposure to acceptable levels during standing position. However during sitting position reduction of exposure was smaller. It can be concluded that welder position and the correct positioning of LEV should be implemented for effective exposure reduction.
Abstract: A three-dimensional finite element modeling for austenitic stainless steel AISI 304 annealed condition sheets of 1.0 mm thickness are developed using ABAQUS® software. This includes spot welded and weld bonded joints models. Both models undergo thermal heat caused by spot welding process and then are subjected to axial load up to the failure point. The properties of elastic and plastic regions, modulus of elasticity, fracture limit, nugget and heat affected zones are determined. Complete loaddisplacement curve for each joining model is obtained and compared with the experiment data and with the finite element models without including the effect of thermal process. In general, the results obtained for both spot welded and weld-bonded joints affected by thermal process showed an excellent agreement with the experimental data.
Abstract: Friction-stir welding has received a huge interest in the last few years. The many advantages of this promising process have led researchers to present different theoretical and experimental explanation of the process. The way to quantitatively and qualitatively control the different parameters of the friction-stir welding process has not been paved. In this study, a refined energybased model that estimates the energy generated due to friction and plastic deformation is presented. The effect of the plastic deformation at low energy levels is significant and hence a scale factor is introduced to control its effect. The predicted heat energy and the obtained maximum temperature using our model are compared to the theoretical and experimental results available in the literature and a good agreement is obtained. The model is applied to AA6000 and AA7000 series.
Abstract: Arc welding is an important joining process widely used in many industrial applications including production of automobile, ships structures and metal tanks. In welding process, the moving electrode causes highly non-uniform temperature distribution that leads to residual stresses and different deviations, especially buckling distortions in thin plates. In order to control the deviations and increase the quality of welded plates, a fixture can be used as a practical and low cost method with high efficiency. In this study, a coupled thermo-mechanical finite element model is coded in the software ANSYS to simulate the behavior of thin plates located by a 3-2-1 positioning system during the welding process. Computational results are compared with recent similar works to validate the finite element models. The agreement between the result of proposed model and other reported data proves that finite element modeling can accurately predict the behavior of welded thin plates.
Abstract: In medical therapy, laser has been widely used to conduct cosmetic, tumor and other treatments. During the process of laser irradiation, there may be thermal damage caused by excessive laser exposure. Thus, the establishment of a complete thermal analysis model is clinically helpful to physicians in reference data. In this study, porcine liver in place of tissue was subjected to laser irradiation to set up the experimental data considering the explored impact on surface thermal field and thermal damage region under different conditions of power, laser irradiation time, and distance between laser and porcine liver. In the experimental process, the surface temperature distribution of the porcine lever was measured by the infrared thermal imager. In the part of simulation, the bio heat transfer Pennes-s equation was solved by software SYSWELD applying in welding process. The double ellipsoid function as a laser source term is firstly considered in the prediction for surface thermal field and internal tissue damage. The simulation results are compared with the experimental data to validate the mathematical model established here in.
Abstract: The paper deals with determination of electromagnetic
and temperature field distribution of induction heating system used
for pipe brazing. The problem is considered as coupled – time
harmonic electromagnetic and transient thermal field. It has been
solved using finite element method. The detailed maps of
electromagnetic and thermal field distribution have been obtained.
The good understanding of the processes in the considered system
ensures possibilities for control, management and increasing the
efficiency of the welding process.
Abstract: This paper reports the fatigue crack growth behaviour
of gas tungsten arc, electron beam and laser beam welded Ti-6Al-4V
titanium alloy. Centre cracked tensile specimens were prepared to
evaluate the fatigue crack growth behaviour. A 100kN servo
hydraulic controlled fatigue testing machine was used under constant
amplitude uniaxial tensile load (stress ratio of 0.1 and frequency of
10 Hz). Crack growth curves were plotted and crack growth
parameters (exponent and intercept) were evaluated. Critical and
threshold stress intensity factor ranges were also evaluated. Fatigue
crack growth behaviour of welds was correlated with mechanical
properties and microstructural characteristics of welds. Of the three
joints, the joint fabricated by laser beam welding exhibited higher
fatigue crack growth resistance due to the presence of fine lamellar
microstructure in the weld metal.
Abstract: This paper presents a portable robot that is to use for
welding process in shipbuilding yard. It has six degree of freedom and
3kg payload capability. Its weight is 21.5kg so that human workers can
carry it to the work place. Its body mainly made of magnesium alloy
and aluminum alloy for few parts that require high strength. Since the
distance between robot and controller should be 50m at most, the robot
controller controls the robot through EtherCAT. RTX and KPA are
used for real time EtherCAT control on Windows XP. The
performance of the developed robot was satisfactory, in welding of U
type cell in shipbuilding yard.
Abstract: Resistance spot welding process comprises of electric,
thermal and mechanical phenomenon, which makes this process
complex and highly non-linear and thus, it becomes difficult to model
it. In order to obtain good weld nugget during spot welding, hit and
trial welds are usually done which is very costly. Therefore the
numerical simulation research has been conducted to understand the
whole process. In this paper three different cases were analyzed by
varying the tip contact area and it was observed that, with the
variation of tip contact area the nugget formation at the faying
surface is affected. The tip contact area of the welding electrode
becomes large with long welding cycles. Therefore in order to
maintain consistency of nugget formation during the welding process,
the current compensation in control feedback is required. If the
contact area of the welding electrode tip is reduced, a large amount of
current flows through the faying surface, as a result of which
sputtering occurs.
Abstract: In this paper, the strength of a stabilizer is determined when the static and fatigue multiaxial loading are applied. Stabilizer is a part of suspension system in the heavy truck for stabilizing the cabin against the vibration of the road which composes of a thin-walled tube joined to a forge component by fillet weld. The component is loaded by non proportional random sequence of torsion and bending. Residual stress of welding process is considered here for static loading. This static loading with road irregularities are applied in this study as fatigue case that can affected in the fillet welded area of this part. The stresses in the welded structure are calculated using FEA. In addition, the fatigue with multi axial loading in the fillet weld is also investigated and the critical zone of the stabilizer is specified and presented by graphs. Residual stresses that have been resulted by the thermal forces are considered in FEA. Force increasing is the element of finding the critical point of the component.
Abstract: Friction Stir Welding (FSW) is a solid state welding
process invented and patented by The Welding Institute (TWI) in the
United Kingdom in 1991 for butt and lap welding of metals and plastics. This paper highlights the benefits of friction stir welding
process as an energy efficient and a green technology process in the
field of welding. Compared to the other conventional welding processes, its benefits, typical applications and its use in joining
similar and dissimilar materials are also presented.
Abstract: This paper presents kinematic and dynamic analysis of a novel 8-DOF hybrid robot manipulator. The hybrid robot manipulator under consideration consists of a parallel robot which
is followed by a serial mechanism. The parallel mechanism has three translational DOF, and the serial mechanism has five DOF so that the overall degree of freedom is eight. The introduced
manipulator has a wide workspace and a high capability to reduce
the actuating energy. The inverse and forward kinematic solutions are described in closed form. The theoretical results are verified by
a numerical example. Inverse dynamic analysis of the robot is presented by utilizing the Iterative Newton-Euler and Lagrange dynamic formulation methods. Finally, for performing a multi-step
arc welding process, results have indicated that the introduced manipulator is highly capable of reducing the actuating energy.
Abstract: Undoubtedly, chassis is one of the most important
parts of a vehicle. Chassis that today are produced for vehicles are
made up of four parts. These parts are jointed together by screwing.
Transverse parts are called cross member.
This study reviews the stress generated by cyclic laboratory loads
in front cross member of Peugeot 405. In this paper the finite element
method is used to simulate the welding process and to determine the
physical response of the spot-welded joints. Analysis is done by the
Abaqus software.
The Stresses generated in cross member structure are generally
classified into two groups: The stresses remained in form of residual
stresses after welding process and the mechanical stress generated by
cyclic load. Accordingly the total stress must be obtained by
determining residual stress and mechanical stress separately and then
sum them according to the superposition principle.
In order to improve accuracy, material properties including
physical, thermal and mechanical properties were supposed to be
temperature-dependent. Simulation shows that maximum Von Misses
stresses are located at special points. The model results are then
compared to the experimental results which are reported by
producing factory and good agreement is observed.