THERMAL SCIENCE

International Scientific Journal

Mišo B. Bjelić

,

Karel Kovanda

,

Ladislav Kolařík

,

Miomir N. Vukićević

,

Branko S. Radičević

NUMERICAL MODELING OF TWO-DIMENSIONAL HEAT-TRANSFER AND TEMPERATURE-BASED CALIBRATION USING SIMULATED ANNEALING OPTIMIZATION METHOD: APPLICATION TO GAS METAL ARC WELDING

ABSTRACT
Simulation models of welding processes allow us to predict influence of welding parameters on the temperature field during welding and by means of temperature field and the influence to the weld geometry and microstructure. This article presents a numerical, finite-difference based model of heat transfer during welding of thin sheets. Unfortunately, accuracy of the model depends on many parameters, which cannot be accurately prescribed. In order to solve this problem, we have used simulated annealing optimization method in combination with presented numerical model. This way, we were able to determine uncertain values of heat source parameters, arc efficiency, emissivity and enhanced conductivity. The calibration procedure was made using thermocouple measurements of temperatures during welding for P355GH steel. The obtained results were used as input for simulation run. The results of simulation showed that represented calibration procedure could significantly improve reliability of heat transfer model. [National CEEPUS Office of Czech Republic (project CIII-HR-0108-07-1314) and to the Ministry of Education and Science of the Republic of Serbia (project TR37020)]
KEYWORDS
GMAW, heat-transfer, temperature, simulated annealing, optimization, calibration
PAPER SUBMITTED: 2015-04-15
PAPER REVISED: 2015-08-10
PAPER ACCEPTED: 2015-08-10
PUBLISHED ONLINE: 2015-09-06
DOI REFERENCE: https://doi.org/10.2298/TSCI150415127B
CITATION EXPORT: view in browser or download as text file
THERMAL SCIENCE YEAR 2016, VOLUME 20, ISSUE Issue 2, PAGES [655 - 665]
REFERENCES
  1. Rosenthal, D., The theory of moving sources of heat and its application to metal treatments. Transactions ASME, 43 (1946), 11, pp. 849-866.
  2. Rykalin, N.N., Raschety teplovykh protsessov pri svarke - in Russian (Calculations of thermal processes in welding), Mashgiz, Moscow, 1951
  3. Wu, C.S., Welding thermal processes and weld pool behaviors, Taylor & Francis, Boca Raton-Florida, USA, 2011
  4. Myers, P.S., et al., Fundamentals of heat flow in welding. Welding Research Council Bulletin, (1967), 123, pp. 1-47.
  5. Pavelic, V., et al., Experimental and computed temperature histories in gas tungsten-arc welding of thin plates. WELD J, 48 (1969), 7, pp. 295s-305s.
  6. Hibbitt, H.D., Marcal, P. V., A numerical, thermo-mechanical model for the welding and subsequent loading of a fabricated structure. Computers & Structures, 3 (1973), 5, pp. 1145-1174.
  7. Krutz, G.W., Segerlind, L.J., Finite element analysis of welded structures. Welding Journal Research Supplement, (1978), p. 211s-216s.
  8. Kim, C.H., et al., Modeling of temperature field and solidified surface profile during gas-metal arc fillet welding. Journal of Applied Physics, 94 (2003), 4, pp. 2667-2679. DOI: 10.1063/1.1592012
  9. Kumar, A., DebRoy, T., Heat transfer and fluid flow during gas-metal - arc fillet welding for various joint configurations and welding positions. Metallurgical and Materials Transactions A, 38 (2007), 3, pp. 506-519. DOI: 10.1007/s11661-006-9083-4
  10. Traidia, A., Roger, F., Numerical and experimental study of arc and weld pool behaviour for pulsed current GTA welding. International Journal of Heat and Mass Transfer, 54 (2011), 9-10, pp. 2163-2179. DOI: 10.1016/j.ijheatmasstransfer.2010.12.005
  11. Pardo, E., Weckman, D.C., Prediction of weld pool and reinforcement dimensions of GMA welds using a finite-element model. Metallurgical Transactions B, 20 (1989), 6, pp. 937-947.
  12. Quinn, T.P., et al., Coupled arc and droplet model of GMAW. Science and Technology of Welding & Joining, 10 (2005), 1, pp. 113-119. DOI: 10.1179/174329305X29492
  13. Hu, J., Tsai, H.L., Modelling of transport phenomena in 3D GMAW of thick metals with V groove. Journal of Physics D: Applied Physics, 41 (2008), 6, p. 065202. DOI: 10.1088/0022-3727/41/6/065202
  14. Xu, G., et al., Three-dimensional modeling of arc plasma and metal transfer in gas metal arc welding. International Journal of Heat and Mass Transfer, 52 (2009), 7-8, pp. 1709-1724. DOI: 10.1016/j.ijheatmasstransfer.2008.09.018
  15. Schnick, M., et al., Modelling of gas-metal arc welding taking into account metal vapour. Journal of Physics D: Applied Physics, 43 (2010), 43, p. 434008. DOI: 10.1088/0022-3727/43/43/434008
  16. Mishra, S., Tailoring weld geometry and composition in fusion welding through convective mass transfer calculations, Ph. D. thesis, The Pennsylvania State University, Philadelphia, USA, 2006.
  17. Pittner, A. A., contribution to the solution of the inverse heat conduction problem in welding simulation, Ph. D. thesis, Technischen Universität Berlin, Berlin, 2012.
  18. Kumar, A., DebRoy, T., Guaranteed fillet weld geometry from heat transfer model and multivariable optimization. International Journal of Heat and Mass Transfer, 47 (2004), 26, pp. 5793-5806. DOI: 10.1016/j.ijheatmasstransfer.2004.06.038
  19. Kumar, A., DebRoy, T., Tailoring fillet weld geometry using a genetic algorithm and a neural network trained with convective heat flow calculations. Welding journal, 86 (2007), 1, pp. 26s-33s.
  20. Kumar, A., DebRoy, T., Improving reliability of modelling heat and fluid flow in complex gas metal arc fillet welds—part II: application to welding of steel. Journal of Physics D: Applied Physics, 38 (2005), 1, pp. 127-134. DOI: 10.1088/0022-3727/38/1/020
  21. Pittner, A. et al., Fast temperature field generation for welding simulation and reduction of experimental effort. Welding in the World, 55 (2013), 9-10, pp. 83-90. DOI: 10.1007/BF03321324
  22. Bjelić, M., Simulation of temperature field during GMA welding of thin sheets, M. Sc. thesis, University of Kragujevac, Kraljevo, Serbia, 2009.
  23. Çengel, Y.A., Heat transfer: A practical approach. McGraw-Hill, New York, USA, 2003
  24. Miettinen, J., Louhenkilpi, S. Calculation of thermophysical properties of carbon and low alloyed steels for modeling of solidification processes. Metallurgical and Materials Transactions B, 25 (1994), 6, pp. 909-916. DOI: 10.1007/BF02662773
  25. Andrews, K.W., Empirical formulae for the calculation of some transformation temperatures. J. Iron Steel Inst, 203 (1965), 7, pp. 721-727.
  26. Guthmann, K., Günstige Gießtemperatur im Vergleich zum Erstarrungspunkt von Eisen und Stahlschmelzen. Stahl und Eisen, 71 (1951), pp. 399-402.
  27. Takeuchi, E., Brimacombe, J.K., Effect of oscillation-mark formation on the surface quality of continuously cast steel slabs. Metallurgical Transactions B, 16 (1985), 3, pp. 605-625. DOI: 10.1007/BF02654859
  28. Jablonka, A. et al., Thermomechanical properties of iron and iron-carbon alloys: density and thermal contraction. Steel research, 62 (1991), 1, pp. 24-33.
  29. De Oliveira, W.P. et al., Thermomechanical analysis of steel cylinders quenching using a constitutive model with diffusional and non-diffusional phase transformations. Mechanics of Materials, 42 (2010), 1, pp. 31-43. DOI: 10.1016/j.mechmat.2009.09.006
  30. Ariza, E.A. et al., Numerical simulation with thorough experimental validation to predict the build-up of residual stresses during quenching of carbon and low-alloy steels. ISIJ International, 54 (2014), 6, pp. 1396-1405. DOI: 10.2355/isijinternational.54.1396
  31. Rao, S.S., Engineering Optimization: Theory and Practice. John Wiley & Sons, New Jersey
  32. Yang, X.-S., Engineering optimization: an introduction with metaheuristic applications. John Wiley & Sons, New Jersey, USA, 2010
PDF VERSION [DOWNLOAD]
Numerical modeling of two-dimensional heat-transfer and temperature-based calibration using simulated annealing optimization method: Application to gas metal arc welding

© 2024 Society of Thermal Engineers of Serbia. Published by the Vinča Institute of Nuclear Sciences, National Institute of the Republic of Serbia, Belgrade, Serbia. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution-NonCommercial-NoDerivs 4.0 International licence