NARROW GROOVE SAW SIMULATION

Submitted to: Dr. S. A. Channiwala Professor, Mech. Engg. Deptt. S. V. N. I. T, Surat

Literature of SIMULATION
Welding is complex physical and chemical processes that include

electric arc physics heat transfer metallurgy and mechanics, if we

adopt the experimental method and often cause result lack of regularity because of many factors influence, and with longer time

and higher costs .

During arc welding, due to uneven heating and cooling cycles, complex thermal stress and strains are produced resulting in

residual stresses and distortions .

During welding, the interaction of the heat source with the material results

in melting, vaporization , solidification, subsequent solid-state

transformation stresses, and distortions . Since most of the fusion welding processes are fast and are completed within a few minutes, experimental measurement of all of processes and their interactions are very difficult. In this regard, computer modelling has been a very valuable method to evaluate the physics , chemistry, and the mechanics of the process. In modelling welding processes,

phenomenological models are used to seek insight into various aspects

of the processes .

 Like any other fusion welding process the heat supplied during SAW is responsible for the changes in the microstructures, and development of residual stresses and distortions.

Welding process parameters like

Electrode diameter
Electrode travel speed Thickness of the work piece, Current and voltage

greatly affect the temperature distribution patterns and hence

residual stresses and distortions .

 With hot structure coupling function of FEM to analysis welding

process cloud overcome the shortcomings of experimental methods,

which is effective method to research the variation of welding deformation and residual stress that provide the basis for choice

welding manner and technology parameter reasonable .

A large number of models have been reported in the published

literature to predict temperature distributions , residual stresses and distortions in the welded joints .

 Most of them have concentrated on a 2-D approximation of a3-D problem . Kamala and Goldak opined that a two-dimensional (2-D) approximation of a three-dimensional(3-D) problem is not

appropriate to predict temperature distribution, residual stresses

and distortion patterns

 The important process characteristics which are required to be considered in any simulation are: (1) Moving heat source, (2) Arc travel speed, (3) Current and voltage, (4) Temperature-dependent material properties (5) Deposition of filler material and

(6) geometrical constraints .

 To minimize computational time and cost, an axi-symmetric

modeling approach is adopted widely for welding simulation .

However, recent investigations have advocated 3-D solid modeling without considering the axi-symmetry for better prediction of

distortions and residual stresses .

To simulate the filler material deposition, the Element Birth and Death approach has been used in the numerical model .

 In this technique the elements are activated or deactivated as the

welding heat source moves along the weld line.

The model was further verified by comparing the predicted and experimentally obtained temperature distributions and angular distortions .

MODELING METHODOLOGY
THERMAL MODEL
STRUCTURAL MODEL

 In the thermal analysis, both the preheating and the inter-pass

temperature were taken into account. A surface and volumetric heat

source with a Gaussian density distribution was used in order to describe the heat input of the welding arc and the melt droplets . The arc efficiency factor and the energy distribution between the surface and volume were adjusted according to the size of the weld pool from the weld micro-section .
For the boundary conditions during the thermal analysis, convection, radiation and the contact with the clamping tools were considered

THERMAL MODEL
The heat source was modelled as a distributed heat flux depending on

arc spread.

The rate of arc travel, current and voltage were varied and these parameters were noted along with the temperature data.

It is not possible to measure the spread of the arc in the SAW process because it is covered with flux granules.

THERMAL MODEL
However the radius of arc spread was estimated by considering the

electrode diameter and bead widths of welds formed during

experiments This arc radius was used for transient thermal analysis with the

moving arc and the temperature profiles were verified with the
experimentally measured ones . After obtaining the temperature profiles for each job coupled thermomechanical analyses were carried out for predicting the angular distortion .

THERMAL MODEL
The moving heat load applied in the finite element model is taken as a distributed heat flux as given by

where r is the region in which 95% of the heat flux is concentrated .

Q is the arc power (W), is the arc efficiency, V is the arc voltage and I is the arc current

THERMAL MODEL
The moving heat load was applied on the area bounded by the weld lines and except for this area other areas of the plate are subjected to heat loss due to convection. In this analysis the convection loss is taken as 15W/m2K .

ASUMPTIONSS
The following assumptions were made in the present finite element analysis : (1) Density is not affected due to thermal expansion. (2) Linear Newtonian convective cooling was assumed. No forced convection was considered. (3) Convective cooling was assumed on all the surfaces excepting the weld zone.

THERMAL MODEL
(4) The heat source was assumed to have a Gaussian distribution of heat flux. (5) Arc efficiency is 90% was taken to account for other losses .

The governing differential equation for heat conduction in a solid without heat generation is given by

BOUNDARY CONDITIONS
FIRST BOUNDARY CONDITION :
A specified initial temperature covering the entire plate surface is

where T is the ambient temperature. Energy balance at the work surface leads to the second and third boundary conditions.
Let S1 represents the zone where the arc heat is applied. The rest of the plate represented by S2 is exposed to atmosphere where heat loss takes place due to convection .

SECOND BOUNDARY CONDITION

The arc heat acting over the surface S1, is given by

THIRD BOUNDARY CONDITION

The heat loss due to convection over S2 is given by

To avoid the sharp change in the value of specific heat with melting, enthalpy was used as the material property. This was done by defining the enthalpy of a material as a function of temperature .

STRUCTURAL MODEL
In the mechanical analysis, the elastic- viscoplastic temperature
dependant material behaviour including the phase dependant dilatation and the transformation-induced plasticity is considered

The stress strain relationship can be represented as

STRUCTURAL MODEL
By considering the principle of virtual work it can be written as

In the case of nonlinear materials E can be written as

The solution was obtained using ANSYS . Coupled transient thermal and nonlinear structural analysis was done for predicting distortion.

STRUCTURAL MODEL

Overview of experimental and modelling tools required for weld microstructure modelling

SIMULATION SOFTWARES FOR WELDING

ANSYS ABAQUS HYPERWORKS MARC WELDSIM VIRTUAL WELDSHOP (VWS) SYSWELD FORTRAN 77 PROE

 PROE :
For modeling

HYPER WORKS AND MARC : For meshing ANSYS AND ABAQUS : For analysis (solving )

The birth and death techniques

If material is added to or removed from a system, certain elements

in your model may become "existent" or "nonexistent. In such

cases, you can employ element birth and death options to deactivate or reactivate selected elements, respectively .

The birth and death feature is available in the ANSYS Multi-physics, ANSYS Mechanical and ANSYS Structural products

The birth and death techniques

To achieve the "element death" effect, the ANSYS program does not

actually remove "killed" elements. Instead, it deactivates them by

multiplying their stiffness (or conductivity, or other analogous quantity) by a severe reduction factor (ESTIF). This factor is set to

1.0E-6 by default, but can be given other values .

Element loads associated with deactivated elements are zeroed out of the load vector, however, they still appear in element-load lists.

Similarly, mass, damping, specific heat, and other such effects are
set to zero for deactivated elements.

The birth and death techniques

The mass and energy of deactivated elements are not included in

the summations over the model. An element's strain is also set to

zero as soon as that element is killed . In like manner, when elements are "born," they are not actually

added to the model; they are simply reactivated. You must create all
elements, including those to be born in later stages of your analysis, while in PREP7. You cannot create new elements in SOLUTION. To

"add" an element, you first deactivate it, then reactivate it at the

proper load step .

The birth and death techniques :

When an element is reactivated, its stiffness, mass, element loads, etc. return to their full original values. Elements are reactivated with no record of strain history (or heat storage, etc.); however, initial strain defined as a real constant (for elements such as LINK1) will not be affected by birth and death operation : This capability is useful for modelling effects due to phase changes (as in welding processes, when structurally inactive molten material solidifies and becomes structurally active).

ELEMENT SUPPORTING BIRTH AND DEATH FEATURES

REFERENCE
Ansys Tutorial Radaj D. Welding residual stresses and distrotion Calculation and measurement. Dssel dorf: DVS-Verlag; 2003 . Mandal NR. Welding and distortion control, 1st ed. New Delhi,India: Narosa Publishing House; 2004. Lindgren LE. Finite element modelling and simulation of welding Part1: increased complexity. J Thermal Stresses 2001;24:14192.

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