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and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 2, July-December (2012), © IAEME
RESEARCH AND DEVELOPMENT (IJIERD)
ISSN 0976 – 6979 (Print)
ISSN 0976 – 6987 (Online)
Volume 3, Issue 2, July-December (2012), pp. 42-50
IJIERD
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EFFECT OF HEAT INPUT AND SPEED OF WELDING ON

DISTORTION IN MIG WELDING

1 2 3
Mr. Harshal K. Chavan Mr. Gunwant D. Shelake Dr. M. S. Kadam
M.E. (Manufacturing) M.E. (Manufacturing) HOD (Mechanical Department)
JNEC Aurangabad (M.S.) JNEC Aurangabad (M.S.) JNEC Aurangabad (M.S.)
harshal.k.chavan@gmail.com gunwantshelake@gmail.com mdaskadam@rediffmail.com

ABSTRACT
The objective of this research is to simulate the complex arc welding process by using the
finite element method(ANSYS)[ଵ] . After the model is built and verified, the main objective of
the research is to study the effects of varying the welding process parameters on the thermo-
mechanical responses. In addition to that, the aim of this research is also to find a relationship
between welding parameters and thermo-elasto-plastic responses.

In this research paper, the responses of single pass corner-joint of arc welding are evaluated
through the finite element software (ANSYS). The study of this research paper covers only
the effects of varying heat input, welding speed on the thermo mechanical responses of the
weldment after cooling down to room temperature.
Keywords: - Heat, Weld speed, Distortion, strain, FEA

INTRODUCTION
The problem of welding distortion during large steel fabrications causes to the dimensional
inaccuracies and misalignments of structural members, which can result in corrective tasks or
rework when tolerance limits are exceeded. This in turn, increases the production cost and
leads to delays. In fabrication and design industries, expenses for rework such as
straightening could cost lacks of Rupees. Therefore, the problems of distortion and residual
stresses are always of great concern in welding industry. In order to deal with this problem, it
is necessary to define prediction of the amount of distortion resulting from the welding
operations. One way to predict the distortion and shrinkage of steel welding is through
numerical analysis such as finite element analysis (FEA). Once the techniques of prediction
of the distortion and shrinkage are identified, then the problems can be controlled
accordingly.

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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 2, July-December (2012), © IAEME

Within the welding procedures, there are many factors such as welding process type,
welding process parameters, welding sequence, preheat patterns, level of constraint and joint
details that contribute to the distortion of the welded structure. Knowing which parameters
have a major effect on the quality of the weld and which parameters give the most
significant effects on the weld quality are the main issues in welding industry. The research
activity in welding simulation started decades ago. Rosenthal (1941,1946)[37,39,41] was among
the first researchers to develop an analytical solution of heat flow during welding based on
conduction heat transfer for predicting the shape of the weld pool for two and three-
dimensional welds. Understanding of the theory of heat flow is essential in order to study the
welding process analytically, numerically or experimentally since the pioneering work of
Rosenthal (1946), considerable interest in the thermal aspects of welding was expressed by
many researchers such as. Chen et al. (2003)[10] Andrea Capriccioli, (2009)[12] ,and Heinze
et al. (2012)[13].

PROCEDURE FOR FINITE ELEMENT MODEL

Present work requires that finite element model be created to study the effect of process
parameter on , deformation, residual stress & strain. We must setup a transient thermal
analysis to determine thermal state in the weld and surrounding components. Following this
we are required to import the thermal loading to setup structural analysis which results in
deformation, residual stress & strain. The weldment material properties employed in this
paper were mild steel, which were taken from Andrea Capriccioli et al. (2009)[12].To simplify
the heat transfer analysis, Dean Denga,(2007)[2] , Bonifaz (2000)[40] , assumptions were
made. The heat input from weld electrode is modeled by using heat flux as input from
electrode to weld surface and is depends on the efficiency of arc and welder setting. The heat
flux distribution on the surface of weldment is given by Goldak et al. (1986) [30]

RESULT

Effect of Heat Input

Heat input is one of the most important process parameters in controlling weld response. It
can be referred to as an electrical energy supplied by the welding arc to the weldment. In
practice, however, heat input can approximately (i.e., if the arc efficiency is not taken into
consideration) be characterized as the ratio of the arc power supplied to the electrode to the
arc travel speed, as shown in the following equation.

×I×
Q=V× ×60/υ……………….

Where, I is welding current; V is welding arc voltage; v is the arc welding speed, and Q is the
heat input. In this work, the effect of heat input on welding responses was evaluated using
three values (heat input in Watt), characterized as low, medium, and high. Table 1 illustrates
the values used for the analyses. This evaluation was carried out by considering the rest of

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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 2, July-December (2012), © IAEME

parameters; welding speed was kept constant at low value and restraint was kept constant at
high value.

Table 1 Range of heat input used for FEA [27]

LOW MEDIUM HIGH

1278W 1448W 1704W
HEAT FLUX CALCULATION FOR FEA

Voltage and current values for High, medium & low heat flux

1) For High Heat Flux

Welding Voltage 14.2 V 2) For Medium Heat Flux
Welding Voltage 14.2 V
Welding Current 20 A
Welding Current 17 A

3) For Low Heat Flux

Welding Voltage 14.2 V

Welding Current 15 A

Electrode Diameter = 25.4/8 = 3.175 mm

Area of electrode = 3.1416×3.175×3.175/4 = 7.9173mm2 = 0.0000079173 m2

Q= I×V×60/ν

1) HIGH
Q=20×14.2×60/10= 1704W

q=Q/a= 1704/0.0000079173= 2.15e8W/m2

2) MEDIUM

Q=17×14.2×60/10=1448W

q=Q/a= 1448/0.0000079173= 1.82e8W/m2

3) LOW
Q=15×14.2×60/10 = 1278W
q=Q/a = 1278/0.0000079173= 1.61e8 W/m2

(Where q is heat input per unit area, a is area and Q is Heat input)

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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 2, July-December
December (2012), © IAEME

ANALYSIS OF RESULTS
Fig 1 shows that x elastic strain and y elastic strains are sensitive to heat input. As heat input
changes strain changes respectively.
Fig 2 shows that stress value decreases as heat input increases. This is due to fact that we
cannot consider cooling time in the solution. As we can see from the graph that X-stress
X in
the vertical plate is more sensitive to the heat input. Also we can see that Y-stress Y in
horizontal
ntal plate is more sensitive to heat input as compare to other directional stresses.
As heat input increases stresses decreases, this is due to the fact material properties such as
young’s modulus decreases as temperature in the material increases. As the heat input
increases temperature generates in the plate increases and thus the stress generated decreases.

ANALYSIS OF RESULTS
The effects of varying heat input on the thermo mechanical responses is illustrated in
Figure 1 Obviously, the results showed tthat
hat the welding heat input has significant effect on
the welding responses. When the heat input increases, the responses such as displacements,
strain increase. An increase of 12 % of heat input results in a significant increase in the Y
Y-
displacement (65 %), Z-displacement
displacement (10%), and X X-Elastic strain (15 %).
As shown in figure 1 X- displacements in vertical plate is more sensitive to heat input
as compared to other directional displacement i.e. y and z displacement, from figure it is
observed that maximum displacement occurs at 20mm cross section which is in the heat
affected zone.

Horizontal Plate Vertical Plate

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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 2, July-December
December (2012), © IAEME

Figure 1 Graphs Illustrate the Effects of Varying Heat input on Displacement

EFFECT OF VARIABLE SPEED

Welding speed represents the distance of the torch traveled along the weld line per
unit of time. The heat input is inversely proportional to the welding speed. Therefore,
when the heat input is larger, the welding speed is slower for a constant heat input
rate.
In this research, low, medium, and high welding speeds were investigated
while considering the rest of parameters such as heat input is kept at low value and
restraints at high value.

Table 2 Range of Welding Speed for FEA

LOW MEDIUM HIGH

2mmps 3mmps 4mmps

ANALYSIS OF RESULTS
Figure 2 shows the effect of varying welding speed. From figure it observed that as the
welding speed increases displacement, strain decreases. When welding speed increases
by 33%, X-displacement
displacement of horizontal plate increases by 14% and Z-displacement
displacement of
horizontal plate decreases by 11%.

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International Journal of Industrial Engineering Research and Development (IJIERD), ISSN 0976 –
6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 2, July-December
December (2012), © IAEME

Horizontal plate Vertical Plate

Figure 2 Graph illustrate effect of varying welding speed on Displacement

As the speed of welding increases the stresses induced in the plate decreases because
as welding speed increase time for welding decreases and thus It is noted that the
faster the welding speed is made, the less heat is absorbed by the base metal and thus

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6979(Print), ISSN 0976 – 6987(Online) Volume 3, Issue 2, July-December (2012), © IAEME

stresses induced decreases. The graph also shows the same trend.
CONCLUSION
After completion of this work, several conclusions are made from the results shown
above. Based on the simulation results i.e. results shown above in figures we can
predict the distortion, shrinkages of weldment numerically. This is cost saving process
because experimental processes are costly. From the simulation results we also
conclude that heat input, welding speed has significant impacts on the weld response
which are as follows

When the heat input increases by, the responses such as displacements, strain
increase. An increase of 12 % of heat input results in a significant increase in
the Y-displacement (65 %), Z-displacement (10%), and X-Elastic strain (15
%).

On the other hand, the opposite response behavior is observed when the
welding speed increases. When the welding speed increases by, the responses
such as displacement, strain decreases. An increase of 33% of welding speed
results in a significant decrease in Y-displacement (11%),Z-
displacement(12%),and X-elastic strain(35%).

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