THERMAL SCIENCE

International Scientific Journal

MULTI-OBJECTIVE CALIBRATION OF THE DOUBLE-ELLIPSOID HEAT SOURCE MODEL FOR GMAW PROCESS SIMULATION

ABSTRACT
The scope of application of simulation models in welding is limited by the accuracy of their output results. This paper presents a calibration procedure for a 3-D quasi-stationary model of heat transfer for gas metal arc welding. The double-ellipsoid heat source used in this model has five input parameters whose value cannot be specified accurately. To estimate these values, we employed a multi-objective calibration procedure with two objective functions using the paretosearch optimization algorithm. Objective functions represented the error between simulated and experimentally observed values of penetration depth and weld bead width during gas metal arc welding of P355GH steel plates. All input parameters were assumed to be a power function of line energy. To reduce computational time, we replaced the numerical model with a response surface methodology metamodel based on an optimal set of simulation results from the numerical model. The results of the simulations based on calculated values of input parameters for the heat source model showed excellent matching with the experimental results.
KEYWORDS
PAPER SUBMITTED: 2021-01-31
PAPER REVISED: 2021-03-26
PAPER ACCEPTED: 2021-04-02
PUBLISHED ONLINE: 2021-05-16
DOI REFERENCE: https://doi.org/10.2298/TSCI210131181B
CITATION EXPORT: view in browser or download as text file
THERMAL SCIENCE YEAR 2022, VOLUME 26, ISSUE Issue 3, PAGES [2081 - 2092]
REFERENCES
  1. Goldak, J., et al., A New Finite Element Model For Welding Heat Sources, Metallurgical Transactions B, 15 (1984), 2, pp. 299-305
  2. DuPont, J.N., Marder, A.R., Thermal Efficiency Of Arc Welding Processes, Welding journal., 74 (1995), 12, pp. 406-s-416-s
  3. Haelsig, A., et al., New Findings On The Efficiency Of Gas Shielded Arc Welding, Welding in the World, 56 (2012), 11-12, pp. 98-104
  4. Joseph, A., et al., Measurement And Calculation Of Arc Power And Heat Transfer Efficiency In Pulsed Gas Metal Arc Welding, Science and Technology of Welding and Joining, 8 (2003), 6, pp. 400-406
  5. Wu, C.S., Welding Thermal Processes And Weld Pool Behaviors, Taylor & Francis, Boca Raton-Florida, USA, 2011
  6. Christensen, N., et al., Distribution Of Temperatures In Arc Welding, British Welding Journal, 12 (1965), 2, pp. 54-75
  7. Joshi, S., et al., Characterization Of Material Properties And Heat Source Parameters In Welding Simulation Of Two Overlapping Beads On A Substrate Plate, Computational Materials Science, 69 (2013), pp. 559-565
  8. Chen, B.Q., et al., Numerical And Experimental Studies On Temperature And Distortion Patterns In Butt-Welded Plates, International Journal of Advanced Manufacturing Technology, 72 (2014), 5-8, pp. 1121-1131
  9. Jia, X., et al., A New Method To Estimate Heat Source Parameters In Gas Metal Arc Welding Simulation Process, Fusion Engineering and Design, 89 (2014), 1, pp. 40-48
  10. Goldak, J.A., Akhlaghi, M., Computational Welding Mechanics, Springer, New York, USA, 2005
  11. Nasiri, M.B., Enzinger, N., Powerful Analytical Solution To Heat Flow Problem In Welding, International Journal of Thermal Sciences, 135 (2019), pp. 601-612
  12. Kumar, A., Debroy, T., Tailoring Complex Weld Geometry Through Reliable Heat-Transfer And Fluid-Flow Calculations And A Genetic Algorithm, Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science, 36 (2005), 10, pp. 2725-2735
  13. De, A., A Smart Model To Estimate Effective Thermal Conductivity And Viscosity In The Weld Pool, Journal of Applied Physics, 95 (2004), 9, pp. 5230-5240
  14. Bag, S., et al., Use Of A Multivariate Optimization Algorithm To Develop A Self-Consistent Numerical Heat Transfer Model For Laser Spot Welding, The International Journal of Advanced Manufacturing Technology, 38 (2007), 5-6, pp. 575-585
  15. 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
  16. Gu, Y., et al., Determination Of Parameters Of Double-Ellipsoidal Heat Source Model Based On Optimization Method, Welding in the World, 63 (2019), 2, pp. 365-376
  17. Mijajlovic, M., et al., Effective Temperature Based Algorithm For Achieving Constant Quality Resistance Seam Weld, Thermal Science, (2020), 00, pp. 222-222
  18. Farias, R.M., et al., An Efficient Computational Approach For Heat Source Optimization In Numerical Simulations Of Arc Welding Processes, Journal of Constructional Steel Research, 176 (2021), 106382, pp. 1-13
  19. Lazić, V.N., et al., Numerical Analysis Of Temperature Field During Hardfacing Process And Comparison With Experimental Results, Thermal Science, 18 (2014), suppl.1, pp. S113-S120
  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
  21. Chen, C., et al., Study Of Heat Source Calibration And Modelling For Laser Welding Process, International Journal of Precision Engineering and Manufacturing, 19 (2018), 8, pp. 1239-1244
  22. Bjelić, M., Characterization of weld geometry and microstructure based on heat-transfer and metallurgical model of the GMAW process as a basis for prediction of the technological parameters (in Serbian), Ph. D. thesis, University of Kragujevac, Kraljevo, Serbia, 2016
  23. Martinez-Conesa, E., et al., Optimization Of Geometric Parameters In A Welded Joint Through Response Surface Methodology, Construction & building materials., 154 (2017), pp. 105-114
  24. Correia, D.S., et al., Comparison Between Genetic Algorithms And Response Surface Methodology In GMAW Welding Optimization, Journal of Materials Processing Technology, 160 (2005), 1, pp. 70-76
  25. Islam, M., et al., Simulation-Based Numerical Optimization Of Arc Welding Process For Reduced Distortion In Welded Structures, Finite Elements in Analysis and Design, 84 (2014), pp. 54-64
  26. Bjelić, M.B., et al., Numerical Modeling Of Two-Dimensional Heat-Transfer And Temperature-Based Calibration Using Simulated Annealing Optimization Method: Application To Gas Metal Arc Welding, Thermal Science, 20 (2016), 2, pp. 655-665
  27. Meseguer-Valdenebro, J., et al., Calculation Of T8/5 By Response Surface Methodology For Electric Arc Welding Applications, Thermal Science, 18 (2014), suppl.1, pp. 149-158
  28. Kim, D., et al., Modelling And Optimization Of A GMA Welding Process By Genetic Algorithm And Response Surface Methodology, International Journal of Production Research, 40 (2002), 7, pp. 1699-1711
  29. Kumar, A., DebRoy, T., Tailoring Fillet Weld Geometry Using A Genetic Algorithm And A Neural Network Trained With Convective Heat Flow Calculations, Welding Journal Research Supplement, 86 (2007), 1, pp. 26s-33s
  30. Kumar, A., DebRoy, T., Neural Network Model Of Heat And Fluid Flow In Gas Metal Arc Fillet Welding Based On Genetic Algorithm And Conjugate Gradient Optimisation, Science and Technology of Welding and Joining, 11 (2006), 1, pp. 106-119
  31. Mishra, S., DebRoy, T., A Genetic Algorithm And Gradient - Descent - Based Neural Network With The Predictive Power Of A Heat And Fluid Flow Model For Welding, Welding Journal Research Supplement, 85 (2006), 11, pp. 2315-2425
  32. Ryberg, A.-B., et al., Metamodel-Based Multidisciplinary Design Optimization For Automotive Applications, Linköping University Electronic Press, Linköping, Sweden, 2012
  33. ***, No Title, www.mathworks.com/help/gads/paretosearch-algorithm.html
  34. Nguyen, N.T., Thermal Analysis Of Welds, WIT, Southampton, Boston, USA, 2004

© 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