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A NUMERICAL APPROACH FOR MODELLING THERMAL PROFILES AND EFFECTS OF PROCESS PARAMETERS ON IT IN SUBMERGED ARC WELDING OF AISI 1518 GRADE STEEL

Year 2015, Volume: 1 Issue: 6 - SPECIAL ISSUE 3 INTERNATIONAL CONFERENCE ON ADVANCES IN MECHANICAL ENGINEERING ISTANBUL 2015 (ICAME15), - , 01.06.2015
https://doi.org/10.18186/jte.55588

Abstract

A comprehensive methodology for the analysis of thermal analysis due to welding has been studied in this present investigation. A finite volume methodology (FVM) among term of the basic heat transfer equation was enforced to simulate the temperature profiles in submerged arc welding (SAW) of AISI 1518 grade steel. The supply of the arc is assumed to be a moving conicoidal heat supply with a Gaussian distribution. The obtained results from the simulation methodology are compared with experimental results and determined a good agreement with experimental results, with associate degree overall proportion of error calculable to be between 5.23%. The influence of welding current and speed of temperature analysis has been evaluated and located that each one those parameters are playing a necessary role in moving the temperature distribution of the assembly, i.e.when current inflated, the temperature conjointly inflated with constant speed yet like higher speed temperature is decreased for constant current . Finally, the influence of heat input on peak temperature variations in various welding parameters has been evaluated and shown that the higher heat input in higher temperature is obtained.

References

  • P. T. Houldcroft, Submerged-arc welding: Woodhead Publishing, 1989. [2] D. Rosenthal, "Mathematical theory of heat distribution during welding and cutting," Welding journal, vol. 20, pp. 220s-234s, 1941.
  • D. Rosenthal, "The theory of moving sources of heat and its application to metal treatments," 1946.
  • V. Pavelic, R. Tanbakuchi, O. Uyehara, and P. Myers, "Experimental and computed temperature histories in gas tungsten-arc welding of thin plates," WELD J, vol. 48, p. 295, 1969.
  • T. Eagar and N. Tsai, "Temperature fields produced by traveling distributed heat sources," Welding Journal, vol. 62, pp. 346-355, 1983.
  • M. A. Wahab, M. Painter, and M. Davies, "The prediction of the temperature distribution and weld pool geometry in the gas metal arc welding process," Journal of Materials Processing Technology, vol. 77, pp. 233-239, 1998.
  • S. Murugan, P. Kumar, and B. Raj, "Temperature distribution during multipass welding of plates," International journal of pressure vessels and piping, vol. 75, pp. 891-905, 1998.
  • R. Choo, J. Szekely, and R. Westhoff, "On the calculation of the free surface temperature of gas-tungsten-arc weld pools from first principles: Part I. Modeling the welding arc," Metallurgical Transactions B, vol. 23, pp. 357-369, 1992.
  • H. Fan, H.-L. Tsai, and S. Na, "Heat transfer and fluid flow in a partially or fully penetrated weld pool in gas tungsten arc welding," International Journal of Heat and Mass Transfer, vol. 44, pp. 417-428, 2001.
  • P. Duranton, J. Devaux, V. Robin, P. Gilles, and J. Bergheau, "3D modelling of multipass welding of a 316L stainless steel pipe," Journal of Materials Processing Technology, vol. 153, pp. 457-463, 2004.
  • J. Goldak, A. Chakravarti, and M. Bibby, "A new finite element model for welding heat sources," Metallurgical transactions B, vol. 15, pp. 299-305, 1984.
  • N. Nguyen, A. Ohta, K. Matsuoka, N. Suzuki, and Y. Maeda, "Analytical solutions for transient temperature of semi- infinite body subjected to 3-D moving heat sources," WELDING JOURNAL-NEW YORK-, vol. 78, pp. 265-s, 1999.
  • S. Wen, P. Hilton, and D. Farrugia, "Finite element modelling of a submerged arc welding process," Journal of Materials Processing Technology, vol. 119, pp. 203-209, 2001.
  • S. Jeong and H. Cho, "An analytical solution to predict the transient temperature distribution in fillet arc welds," Welding Journal-Including Welding Research Supplement, vol. 76, p. 223s, 1997.
  • C. K. Takemori, D. T. Muller, and M. A. d. Oliveira, "Numerical simulation of transient heat transfer during welding process," 2010.
  • A. Anca, A. Cardona, J. Risso, and V. D. Fachinotti, "Finite element modeling of welding processes," Applied Mathematical Modelling, vol. 35, pp. 688-707, 2011.
  • S. Bag, A. Trivedi, and A. De, "Development of a finite element based heat transfer model for conduction mode laser spot welding process using an adaptive volumetric heat source," International Journal of Thermal Sciences, vol. 48, pp. 1923-1931, 2009.
  • S. Kumar and S. Bhaduri, "Three-dimensional finite element modeling of gas metal-arc welding," Metallurgical and Materials Transactions B, vol. 25, pp. 435-441, 1994.
  • E. Nart and Y. Celik, "A practical approach for simulating submerged arc welding process using FE method," Journal Of Constructional Steel Research, vol. 84, pp. 62-71, 2013. [20] N. S. Shanmugam, G. Buvanashekaran, K.
  • Sankaranarayanasamy, and S. R. Kumar, "A transient finite
  • element simulation of the temperature and bead profiles of T
  • joint laser welds," Materials & Design, vol. 31, pp. 4528-4542, 2010.
  • S. M. Adedayo and S. Irehovbude, "Numerical simulation of transient temperature in flash butt-welded axi- symmetric circular sections," Journal of Naval Architecture and Marine Engineering, vol. 10, pp. 33-40, 2013.
  • M. H. Al-Sa’ady, M. A. Abdulsattar, and L. S. Al- Khafagy, "Finite difference simulation of low carbon steel manual arc welding," Thermal Science, vol. 15, pp. 207-214, 2011.
  • K. Boo and H. Cho, "Transient temperature distribution in arc welding of finite thickness plates," Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 204, pp. 175-183, 1990.
  • P. Ghadimi, H. Ghassemi, M. Ghassabzadeh, and Z. Kiaei, "Three-dimensional simulation of underwater welding and investigation of effective parameters," Welding journal, vol. 92, 2013.
  • A. Grill, "The thermal history of a composite cylinder girth welded by TIG," International Journal for Numerical Methods in Engineering, vol. 18, pp. 1031-1044, 1982.
  • W. Grzesik and M. Bartoszuk, "Prediction of temperature distribution in the cutting zone using finite difference approach," International Journal of Machining and Machinability of Materials, vol. 6, pp. 43-53, 2009.
  • D. A. S. Alwan, "Reliability of numerical analysis of cooling curves in the fusion zone of submerged arc welding (saw) process," The Iraqi Journal for Mechanical And Material Engineering, vol. 11, pp. 672-682, 2011.
  • S. Patankar, Numerical heat transfer and fluid flow: CRC Press, 1980.
  • M. Kubiak, "Numerical modelling of liquid material flow in the fusion zone of hybrid welded joint."
  • W. Zhang, G. Roy, J. Elmer, and T. DebRoy, "Modeling of heat transfer and fluid flow during gas tungsten arc spot welding of low carbon steel," Journal of Applied Physics, vol. 93, pp. 3022-3033, 2003.
  • G. A. Taylor, M. Hughes, N. Strusevich, and K. Pericleous, computational modelling of welding phenomena," Applied Mathematical Modelling, vol. 26, pp. 311-322, 2002. to the
  • D. B. Darmadi, A. K. Tieu, and J. Norrish, "A validated thermal model of bead-on-plate welding," Heat and Mass Transfer, vol. 48, pp. 1219-1230, 2012.
  • A. Ghosh, S. Chattopadhyaya, and N. Singh, "Prediction of weld bead parameters, transient temperature distribution & HAZ width of submerged arc welded structural steel plates," in Defect and Diffusion Forum, 2012, pp. 405- 409.
  • R. Komanduri and Z. Hou, "Thermal analysis of the arc welding process: Part I. General solutions," Metallurgical and Materials Transactions B, vol. 31, pp. 1353-1370, 2000.
  • B. Chen, M. Adak, and C. G. Soares, "Numerical investigations to study the effect of weld parameters on the temperature-time history in steel plates," Acoustic Analyses Using Matlab® and Ansys®, p. 285, 2014.
  • D. Gery, H. Long, and P. Maropoulos, "Effects of welding speed, energy input and heat source distribution on temperature variations in butt joint welding," Journal of Materials Processing Technology, vol. 167, pp. 393-401, 2005.
  • A. Okada, "Application of melting efficiency and its problems," Journal of Japan Welding Society, vol. 46, pp. 53- 61, 1977.
  • K. Easterling, Introduction to the physical metallurgy of welding: Elsevier, 2013.
  • G. Krutz and L. Segerlind, "Finited Element Analysis of Welded Structures," SAE Technical Paper1976.
  • Pathak AK, Datta GL. Three-dimensional finite element analysis to predict the different zones of microstructures in submerged arc welding. Proc Inst Mech
  • Engrs J Eng Manufact B 2004;218:269–80. .

A NUMERICAL APPROACH FOR MODELLING THERMAL PROFILES AND EFFECTS OF PROCESS PARAMETERS ON IT IN SUBMERGED ARC WELDING OF AISI 1518 GRADE STEEL

Year 2015, Volume: 1 Issue: 6 - SPECIAL ISSUE 3 INTERNATIONAL CONFERENCE ON ADVANCES IN MECHANICAL ENGINEERING ISTANBUL 2015 (ICAME15), - , 01.06.2015
https://doi.org/10.18186/jte.55588

Abstract

A comprehensive methodology for the analysis of thermal analysis due to welding has been studied in this present investigation. A finite volume methodology (FVM) among term of the basic heat transfer equation was enforced to simulate the temperature profiles in submerged arc welding (SAW) of AISI 1518 grade steel. The supply of the arc is assumed to be a moving conicoidal heat supply with a Gaussian distribution. The obtained results from the simulation methodology are compared with experimental results and determined a good agreement with experimental results, with associate degree overall proportion of error calculable to be between 5.23%. The influence of welding current and speed of temperature analysis has been evaluated and located that each one those parameters are playing a necessary role in moving the temperature distribution of the assembly, i.e.when current inflated, the temperature conjointly inflated with constant speed yet like higher speed temperature is decreased for constant current . Finally, the influence of heat input on peak temperature variations in various welding parameters has been evaluated and shown that the higher heat input in higher temperature is obtained.

References

  • P. T. Houldcroft, Submerged-arc welding: Woodhead Publishing, 1989. [2] D. Rosenthal, "Mathematical theory of heat distribution during welding and cutting," Welding journal, vol. 20, pp. 220s-234s, 1941.
  • D. Rosenthal, "The theory of moving sources of heat and its application to metal treatments," 1946.
  • V. Pavelic, R. Tanbakuchi, O. Uyehara, and P. Myers, "Experimental and computed temperature histories in gas tungsten-arc welding of thin plates," WELD J, vol. 48, p. 295, 1969.
  • T. Eagar and N. Tsai, "Temperature fields produced by traveling distributed heat sources," Welding Journal, vol. 62, pp. 346-355, 1983.
  • M. A. Wahab, M. Painter, and M. Davies, "The prediction of the temperature distribution and weld pool geometry in the gas metal arc welding process," Journal of Materials Processing Technology, vol. 77, pp. 233-239, 1998.
  • S. Murugan, P. Kumar, and B. Raj, "Temperature distribution during multipass welding of plates," International journal of pressure vessels and piping, vol. 75, pp. 891-905, 1998.
  • R. Choo, J. Szekely, and R. Westhoff, "On the calculation of the free surface temperature of gas-tungsten-arc weld pools from first principles: Part I. Modeling the welding arc," Metallurgical Transactions B, vol. 23, pp. 357-369, 1992.
  • H. Fan, H.-L. Tsai, and S. Na, "Heat transfer and fluid flow in a partially or fully penetrated weld pool in gas tungsten arc welding," International Journal of Heat and Mass Transfer, vol. 44, pp. 417-428, 2001.
  • P. Duranton, J. Devaux, V. Robin, P. Gilles, and J. Bergheau, "3D modelling of multipass welding of a 316L stainless steel pipe," Journal of Materials Processing Technology, vol. 153, pp. 457-463, 2004.
  • J. Goldak, A. Chakravarti, and M. Bibby, "A new finite element model for welding heat sources," Metallurgical transactions B, vol. 15, pp. 299-305, 1984.
  • N. Nguyen, A. Ohta, K. Matsuoka, N. Suzuki, and Y. Maeda, "Analytical solutions for transient temperature of semi- infinite body subjected to 3-D moving heat sources," WELDING JOURNAL-NEW YORK-, vol. 78, pp. 265-s, 1999.
  • S. Wen, P. Hilton, and D. Farrugia, "Finite element modelling of a submerged arc welding process," Journal of Materials Processing Technology, vol. 119, pp. 203-209, 2001.
  • S. Jeong and H. Cho, "An analytical solution to predict the transient temperature distribution in fillet arc welds," Welding Journal-Including Welding Research Supplement, vol. 76, p. 223s, 1997.
  • C. K. Takemori, D. T. Muller, and M. A. d. Oliveira, "Numerical simulation of transient heat transfer during welding process," 2010.
  • A. Anca, A. Cardona, J. Risso, and V. D. Fachinotti, "Finite element modeling of welding processes," Applied Mathematical Modelling, vol. 35, pp. 688-707, 2011.
  • S. Bag, A. Trivedi, and A. De, "Development of a finite element based heat transfer model for conduction mode laser spot welding process using an adaptive volumetric heat source," International Journal of Thermal Sciences, vol. 48, pp. 1923-1931, 2009.
  • S. Kumar and S. Bhaduri, "Three-dimensional finite element modeling of gas metal-arc welding," Metallurgical and Materials Transactions B, vol. 25, pp. 435-441, 1994.
  • E. Nart and Y. Celik, "A practical approach for simulating submerged arc welding process using FE method," Journal Of Constructional Steel Research, vol. 84, pp. 62-71, 2013. [20] N. S. Shanmugam, G. Buvanashekaran, K.
  • Sankaranarayanasamy, and S. R. Kumar, "A transient finite
  • element simulation of the temperature and bead profiles of T
  • joint laser welds," Materials & Design, vol. 31, pp. 4528-4542, 2010.
  • S. M. Adedayo and S. Irehovbude, "Numerical simulation of transient temperature in flash butt-welded axi- symmetric circular sections," Journal of Naval Architecture and Marine Engineering, vol. 10, pp. 33-40, 2013.
  • M. H. Al-Sa’ady, M. A. Abdulsattar, and L. S. Al- Khafagy, "Finite difference simulation of low carbon steel manual arc welding," Thermal Science, vol. 15, pp. 207-214, 2011.
  • K. Boo and H. Cho, "Transient temperature distribution in arc welding of finite thickness plates," Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 204, pp. 175-183, 1990.
  • P. Ghadimi, H. Ghassemi, M. Ghassabzadeh, and Z. Kiaei, "Three-dimensional simulation of underwater welding and investigation of effective parameters," Welding journal, vol. 92, 2013.
  • A. Grill, "The thermal history of a composite cylinder girth welded by TIG," International Journal for Numerical Methods in Engineering, vol. 18, pp. 1031-1044, 1982.
  • W. Grzesik and M. Bartoszuk, "Prediction of temperature distribution in the cutting zone using finite difference approach," International Journal of Machining and Machinability of Materials, vol. 6, pp. 43-53, 2009.
  • D. A. S. Alwan, "Reliability of numerical analysis of cooling curves in the fusion zone of submerged arc welding (saw) process," The Iraqi Journal for Mechanical And Material Engineering, vol. 11, pp. 672-682, 2011.
  • S. Patankar, Numerical heat transfer and fluid flow: CRC Press, 1980.
  • M. Kubiak, "Numerical modelling of liquid material flow in the fusion zone of hybrid welded joint."
  • W. Zhang, G. Roy, J. Elmer, and T. DebRoy, "Modeling of heat transfer and fluid flow during gas tungsten arc spot welding of low carbon steel," Journal of Applied Physics, vol. 93, pp. 3022-3033, 2003.
  • G. A. Taylor, M. Hughes, N. Strusevich, and K. Pericleous, computational modelling of welding phenomena," Applied Mathematical Modelling, vol. 26, pp. 311-322, 2002. to the
  • D. B. Darmadi, A. K. Tieu, and J. Norrish, "A validated thermal model of bead-on-plate welding," Heat and Mass Transfer, vol. 48, pp. 1219-1230, 2012.
  • A. Ghosh, S. Chattopadhyaya, and N. Singh, "Prediction of weld bead parameters, transient temperature distribution & HAZ width of submerged arc welded structural steel plates," in Defect and Diffusion Forum, 2012, pp. 405- 409.
  • R. Komanduri and Z. Hou, "Thermal analysis of the arc welding process: Part I. General solutions," Metallurgical and Materials Transactions B, vol. 31, pp. 1353-1370, 2000.
  • B. Chen, M. Adak, and C. G. Soares, "Numerical investigations to study the effect of weld parameters on the temperature-time history in steel plates," Acoustic Analyses Using Matlab® and Ansys®, p. 285, 2014.
  • D. Gery, H. Long, and P. Maropoulos, "Effects of welding speed, energy input and heat source distribution on temperature variations in butt joint welding," Journal of Materials Processing Technology, vol. 167, pp. 393-401, 2005.
  • A. Okada, "Application of melting efficiency and its problems," Journal of Japan Welding Society, vol. 46, pp. 53- 61, 1977.
  • K. Easterling, Introduction to the physical metallurgy of welding: Elsevier, 2013.
  • G. Krutz and L. Segerlind, "Finited Element Analysis of Welded Structures," SAE Technical Paper1976.
  • Pathak AK, Datta GL. Three-dimensional finite element analysis to predict the different zones of microstructures in submerged arc welding. Proc Inst Mech
  • Engrs J Eng Manufact B 2004;218:269–80. .
There are 42 citations in total.

Details

Primary Language English
Journal Section Articles
Authors

Abhijit Sarkar This is me

Publication Date June 1, 2015
Submission Date October 23, 2015
Published in Issue Year 2015 Volume: 1 Issue: 6 - SPECIAL ISSUE 3 INTERNATIONAL CONFERENCE ON ADVANCES IN MECHANICAL ENGINEERING ISTANBUL 2015 (ICAME15)

Cite

APA Sarkar, A. (2015). A NUMERICAL APPROACH FOR MODELLING THERMAL PROFILES AND EFFECTS OF PROCESS PARAMETERS ON IT IN SUBMERGED ARC WELDING OF AISI 1518 GRADE STEEL. Journal of Thermal Engineering, 1(6). https://doi.org/10.18186/jte.55588
AMA Sarkar A. A NUMERICAL APPROACH FOR MODELLING THERMAL PROFILES AND EFFECTS OF PROCESS PARAMETERS ON IT IN SUBMERGED ARC WELDING OF AISI 1518 GRADE STEEL. Journal of Thermal Engineering. June 2015;1(6). doi:10.18186/jte.55588
Chicago Sarkar, Abhijit. “A NUMERICAL APPROACH FOR MODELLING THERMAL PROFILES AND EFFECTS OF PROCESS PARAMETERS ON IT IN SUBMERGED ARC WELDING OF AISI 1518 GRADE STEEL”. Journal of Thermal Engineering 1, no. 6 (June 2015). https://doi.org/10.18186/jte.55588.
EndNote Sarkar A (June 1, 2015) A NUMERICAL APPROACH FOR MODELLING THERMAL PROFILES AND EFFECTS OF PROCESS PARAMETERS ON IT IN SUBMERGED ARC WELDING OF AISI 1518 GRADE STEEL. Journal of Thermal Engineering 1 6
IEEE A. Sarkar, “A NUMERICAL APPROACH FOR MODELLING THERMAL PROFILES AND EFFECTS OF PROCESS PARAMETERS ON IT IN SUBMERGED ARC WELDING OF AISI 1518 GRADE STEEL”, Journal of Thermal Engineering, vol. 1, no. 6, 2015, doi: 10.18186/jte.55588.
ISNAD Sarkar, Abhijit. “A NUMERICAL APPROACH FOR MODELLING THERMAL PROFILES AND EFFECTS OF PROCESS PARAMETERS ON IT IN SUBMERGED ARC WELDING OF AISI 1518 GRADE STEEL”. Journal of Thermal Engineering 1/6 (June 2015). https://doi.org/10.18186/jte.55588.
JAMA Sarkar A. A NUMERICAL APPROACH FOR MODELLING THERMAL PROFILES AND EFFECTS OF PROCESS PARAMETERS ON IT IN SUBMERGED ARC WELDING OF AISI 1518 GRADE STEEL. Journal of Thermal Engineering. 2015;1. doi:10.18186/jte.55588.
MLA Sarkar, Abhijit. “A NUMERICAL APPROACH FOR MODELLING THERMAL PROFILES AND EFFECTS OF PROCESS PARAMETERS ON IT IN SUBMERGED ARC WELDING OF AISI 1518 GRADE STEEL”. Journal of Thermal Engineering, vol. 1, no. 6, 2015, doi:10.18186/jte.55588.
Vancouver Sarkar A. A NUMERICAL APPROACH FOR MODELLING THERMAL PROFILES AND EFFECTS OF PROCESS PARAMETERS ON IT IN SUBMERGED ARC WELDING OF AISI 1518 GRADE STEEL. Journal of Thermal Engineering. 2015;1(6).

IMPORTANT NOTE: JOURNAL SUBMISSION LINK http://eds.yildiz.edu.tr/journal-of-thermal-engineering