Modelling of Welding process

Somnath Chattopadhyaya
Department of Mechanical Engineering
IIT/ISM Dhanbad

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 Lesson Objectives
•Classification of Modelling of Welding
process
•Youtube Videos of Modelling of Welding
process

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Introduction
• The rapid progress of computer technology
accelerates and promotes the various advancements
in every field of science and technology.
• The industries involving welding and joining
processes have been using computers in order to
obtain higher productivities and ensure higher joint
qualities in design of products, manufacturing plan,
factory automation, and so on.

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 Introduction
• The combination of CAD/CAM systems and welding robots is a typical
example of practical use in the welding field.
• However, welding procedure specifications instructed to welding robots
have been almost provided on the basis of data-base accumulated in each
factory through qualification tests performed for many essential variables:
- kind of material,
- thickness,
- groove geometry,
- welding process,
- welding position,
- welding current and so on.
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Introduction
• Therefore, as for the weld joint not to be
experienced in the manufacturing cite, it needs lots
of time and cost to carry out the qualification test of
the welding procedure in order to ensure the joint
performance.
• Whereas, thermal cycle during welding operation
causes the weld deformation and/or the
displacement of weld seam line, and also
deteriorates the quality of final products.
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Introduction
• Then, in order to reduce time and expense in the planning
stage before fabrication, the developments of simulation
software for welding process have been actively carried out
in the world.
• The simulation software aims at the engineering tool
supporting for production such as CAD/CAM, developments
of a smart welding machine and an intelligent welding robot,
and education/training for welding engineers and welders.

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Modeling of Welding Process

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 Introduction
• The performance of the simulation software is
governed by several factors: the easiness of
operation, the scope of application, the accuracy
of simulation, etc.
• The application range and/or the simulation
accuracy are dependent on the numerical model
installed into the software.
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 Introduction
• A precise model provides exact solution relevant to the
subjects: selection of welding parameters, penetration shape in
the welding joint designed, time-dependent temperature field,
solidification structure, deformation or residual stress, etc.
• And it also makes clear the complicated arc welding
phenomena.
• Therefore, numerical models of welding process have been
advancing together with spread of high performance personal
computer.

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Performance of Simulation Software

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 Construction of the Numerical Model
• The technical issues affecting on welding phenomena, which must be
considered in the development of theoretical model.
• As a matter of course, when the penetration shape and/or the temperature
distribution of the work are predicted, temperature at each point
corresponding to finite element or mesh in the calculation domain must be
acquired by using numerical model.
• Useful simulation software must enable us to provide temperature
distribution of the work relevant to the practical welding having many
kinds of joint geometries at various welding positions.

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 Construction of the Numerical Model

• And it is necessary to express the features of welding arc as a

heat source for calculation. In the case of Tungsten Inert Gas
(TIG) welding process, heat input distribution and/or arc
pressure distribution must be quantitatively expressed
depending on electric current, arc length and so on.
• In the case of Gas shielded Metal Arc (GMA) welding
process, molten metal transfer from electrode wire definitely
influences on heat transport and fluid motion in weld pool in
addition to heat and plasma jet from the arc

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Construction of the Numerical Model
• But from the viewpoint of engineering application, needs for
numerical simulation are different depending on the software users:
structure-design engineer, production engineer, welding engineer and
so on.
• In other words, it divides into two cases of weld quality prediction
requiring simulation accuracy and supporting tool for suitable
selection of welding condition.
• Accordingly, there are lots of needs to reduce calculation time even if
the accuracy of the calculation results is rough.

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Construction of the Numerical Model

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Construction of the Numerical Model
• On the other hand, from the scientific viewpoint, the physics
of cathode and/or anode, which are interface between arc
plasma and liquid/solid metal and dominate characteristics of
welding arc discharge, must be deeply understood through
development of advanced welding process model.
• In addition to knowledge concerning the electrode
phenomena in the vicinity of the arc discharge, it is
necessary to obtain exact and accurate quantities on physical
properties of base material and welding wire at elevated
temperature.
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 Construction of the Numerical Model

• The arc welding phenomena are associated with

heat transfer by high temperature arc plasma and
molten metal.
• Thermal and electromagnetic fluid phenomena
are governed by the following equations:

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Mass conservation Equation

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Energy Conservation Equation

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Energy Conservation Equation

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Energy Conservation Equation

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Energy Conservation Equation

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Schematic image of the 3D numerical model of
a TIG arc on the flat plate and grooved plate

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 Modeling of TIG Arc Plasma
• Schematic explanations of the 3D numerical model of the TIG arc are
shown.
• Since TIG arc plasma has a wide range of temperatures, the temperature
dependence of the physical properties of the shielding gas cannot be
ignored.
• The figure shows the physical properties of argon gas.
• As seen, density, thermal conductivity, electrical conductivity and so on
are varied depending on temperature.
• For example, as for electrical conductivity, at room temperature gas is
almost electrical insulator but beyond around 4,000 K it acts as electrical
conductor.
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Density, Thermal Conductivity and Temperature in kelvin

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Viscosity, Specific Heat and Temperature in kelvin

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Electrical Conductivity, Radiation loss and Temperature in kelvin

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Video on Welding Power Characteristics in
welding

• https://www.youtube.com/watch?v=ns2-kf_3UN8
• https://www.youtube.com/watch?v=6Hlr-6UuUFw

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