Numerical Simulation for Shaping Feature of Molten Pool in Twin-Arc Submerged Arc Welding

Kuanfang He, Jun Chen, Siwen Xiao

.
Hunan Provincial Key Laboratory of Health Maintenance for Mechanical Equipment, Hunan University of Science and Technology, Xiantan, China.

DOI: 10.4236/ojapps.2012.21005                

Abstract

The notion of ratio of width to length is proposed to describe the shaping feature of molten pool of twin-Arc submerged arc welding accurately, and analyze the law of molten pool variation and weld formation. The temperature field finite element numerical simulation model of twin arc movement is established. The loading form of twin-arc with double ellipsoid heat source is discussed. The molten pool temperature field of twin-arc submerged arc welding is calculated and analyzed under different process parameters. The law of molten pool characteristics influenced by the welding speed, current and voltage of twin-arc submerged arc welding parameters is analyzed. The relation between shaping feature of molten pool and weld formation is discussed according to the ratio of width to length. The results manifested that the width to length ratio of weld pool decreases with the improvement of welding speed, which result in gene- ration of weld defects. The width to length ratio of weld pool is increased by adjusting the proportion of the current, voltage and the distance of the two arcs, which avoids the generation of weld defects.

Keywords

Twin-Arc Submerged Arc Welding; Shaping Feature; Ratio of Width to Length; Numerical Simulation

Conflicts of Interest

The authors declare no conflicts of interest.

References

[1]	D. J. Tusek, “Mathematical Modeling of Melting Rate in Twin-Wire Welding,” Journal of Materials Processing Technology, Vol. 100, No. 1-3, 2000, pp. 250-256. doi:10.1016/S0924-0136(99)00485-9
[2]	H. Q. Li, X. Wang and X. P. Cai, “Developing Status of SAW at Home and Abroad,” Electric Welding Machine, Vol. 36, No. 4, 2006, pp. 1-6.
[3]	J. Dong, C. L. Mo and Q. C. Shan, “The Simulation of the Automatic Welding Temperature Field in the Hidden Arc Butt Joint Welding of 20 Steel Tube,” Transactions of Shenyang Ligong University, Vol. 26, No. 2, 2007, pp. 38-41.
[4]	X. F. Tan and H. Zhang, “Analysis of Temperature and Stress Fields in Welding Process by Thermo-Elastoplastic Finite Element Method,” Journal of Plasticity Engineering, Vol. 11, No. 5, 2004, pp. 71-74.
[5]	C. L. Mo, B. N. Qian and X. M. Guo, “The Development of Models about Welding Heat Sources Calculation,” Transactions of the China Welding Institution, Vol. 22, No. 3, 2001, pp. 93-96.
[6]	W. F. Zhu, Z. Q. Lin and X. M. Lai, “Numerical Analysis of Projection Welding on Auto-Body Sheet Metal Using a Coupled Finite Element Method,” The International Jour- nal of Advanced Manufacturing Technology, Vol. 28, No. 1-2, 2006, pp. 45-52. doi:10.1007/s00170-004-2336-8
[7]	Z, Paley and P. D. Nbbrt, “Computation of Temperatures in Actual Weld Designs,” Welding Journal, Vol. 54 , No. 11, 1975, pp. 385-392.
[8]	T. W. Eager and N. S .Tsai, “Temperature Fields Produced by Traveling Distributed Heat Sources,” Welding Journal, Vol. 62, No. 12, 1983, pp. 346-355.
[9]	G. A. John, “A New Finite Model for Welding Hear Source,” Metallurgical Transactions, Vol. 15, No. 2, 1984, pp. 299-305. doi:10.1007/BF02667333
[10]	Q. G. Meng, “Heat Source Model For Twin Wire Welding,” Chinese Journal of Mechanical Engineering, Vol. 41, No. 4, 2005, pp. 110-113. doi:10.3901/JME.2005.04.110
[11]	H. B. Dong, H. K. Chul and Y. C. Seon, “Numerical Analysis of Welding Residual Stress Using Heat Source Models for the Multi-Pass Weldment,” Korean Society of Mechanical Engineers International Journal, Vol. 16, No. 9, 2002, pp. 1054-1064.
[12]	Z. G. Gao, Y. X. Wu and J. Huang, “Analysis of Weld Pool Dynamic during Stationary Laser-MIG Hybrid Welding,” The International Journal of Advanced Manufacturing Technology, Vol. 44, No. 9-10, 2009, pp. 870- 879. doi:10.1007/s00170-008-1896-4
[13]	M. Zhao and R. Y. Li, “Numerical Analysis of Dynamic Variation of Weld Pool Geometry in Fully-Penetrated TIG Welding,” China Welding, Vol. 17, No. 2, 2008, pp. 47-53.
[14]	S. L Chen, Z. S. Wu and C. R. Liu, “Numerical Simulation of Temperature Field in Deep Penetration Laser Welding of 5A06 Aluminum Cylinder,” China Welding, Vol. 17, No. 4, 2008, pp. 74-78.
[15]	H. J. Aval, A. Farzadi and S. Serajzadeh, “Theoretical and Experimental Study of Microstructures and Weld Pool Geometry during GTAW of 304 Stainless Steel,” The International Journal of Advanced Manufacturing Technology, Vol. 42, No. 11-12, 2009, pp. 1043-1051. doi:10.1007/s00170-008-1663-6
[16]	Z. Q. Lin, Y. B. Li and Y. S. Wang, “Numerical Analysis of a Moving Gas Tungsten Arc Weld Pool with an External Longitudinal Magnetic Field Applied,” The International Journal of Advanced Manufacturing Technology, Vol. 27, No. 3-4, 2005, pp. 288-295. doi:10.1007/s00170-004-2194-4
[17]	W. F. Zhu, Z. Q. Lin and X. M. Lai, “Numerical Analysis of Projection Welding on Auto-Body Sheet Metal Using a Coupled Finite Element Method,” The International Journal of Advanced Manufacturing Technology, Vol. 28, No. 1-2, 2006, pp. 45-52. doi:10.1007/s00170-004-2336-8
[18]	K. F. He, X. J. Li and J. G. Wu, “Three-Dimensional Temperature Field Numerical Simulation of Twin-Arc,” Advanced Materials Research, Vol. 216, 2011, pp. 188- 193. doi:10.4028/www.scientific.net/AMR.216.188
[19]	S. L. Huang, Y Xue and J. X. Zhang, “3D Finite Element Simulation on Stress-Strain Distributions in All Position Root Butt Welding of Pipe,” Transactions of the China Welding Institution, Vol. 27, No. 4, 2006, pp. 73-75.
[20]	H. N. Cai and M. Y. Tang, “FEM Analysis on TIG Welding Temperature Field,” Chinese Journal of Mechanical Engineering, Vol. 32, No. 2, 1996, pp. 34-39.