51,048 research outputs found
Mitigation of welding distortion and residual stresses via cryogenic CO2 cooling - a numerical investigation
Fusion welding remains the most common and convenient fabrication method for large, thinplate welded structures. However, the resulting tendency to out-of-plane distortion exacts severe design and fabrication penalties in terms of poorer buckling performance, lack of fairness in external appearance, poor fit-up and frequent requirements for expensive rework. There are several ways to mitigate welding distortion and this study concentrates on the use of cryogenic CO2 cooling to reduce distortion. A feasible combination of welding process and cooling parameters, was investigated computationally and the resulting effects on final deformation were predicted. Three different computational strategies were developed and applied to butt-welding and fillet-welding processes, with and without the inclusion of cryogenic cooling. In the first method, a fully transient, uncoupled thermo-elastoplastic model was investigated. This method is comprehensive but not readily applicable to predict welding distortions in complex, industrial-scale, welded structures, due to the large computational requirement. More computationally efficient models are needed therefore and two further models of this type are suggested in this study. The results show good agreement between the different models, despite substantial differences in computational budget. In butt-welded plates, a significant decrease in out-of-plane distortion is obtained when cryogenic cooling is applied. In fillet-welded plates, cooling had much less effect on welding distortion. This was largely due to the size and configuration of the test case assemblies and the fact that the attached stiffener greatly increased the overall stiffness and resistance to contraction forces
Assessing carbon dioxide emission reduction potentials of improved manufacturing processes using multiregional input output frameworks
Evaluating innovative process technologies has become highly important within the last decades. As standard tools different Life Cycle Assessment methods have been established, which are continuously improved. While those are designed for evaluating single processes they run into difficulties when it comes to assessing environmental impacts of process innovations at macroeconomic level. In this paper we develop a multi-step evaluation framework building on multi regional input–output data that allows estimating macroeconomic impacts of new process technologies, considering the network characteristics of the global economy.
Our procedure is as follows: i) we measure differences in material usage of process alternatives, ii) we identify where the standard processes are located within economic networks and virtually replace those by innovative process technologies, iii) we account for changes within economic systems and evaluate impacts on emissions.
Within this paper we exemplarily apply the methodology to two recently developed innovative technologies: longitudinal large diameter steel pipe welding and turning of high-temperature resistant materials. While we find the macroeconomic impacts of very specific process innovations to be small, its conclusions can significantly differ from traditional process based approaches. Furthermore, information gained from the methodology provides relevant additional insights for decision makers extending the picture gained from traditional process life cycle assessment.DFG, SFB 1026, Sustainable Manufacturing - Globale Wertschöpfung nachhaltig gestalte
A model comparison to predict heat transfer during spot GTA welding
The present work deals with the estimation of the time evolution of the weld fusion boundary. This moving boundary is the result of a spot GTA welding process on a 316L stainless steel disk. The estimation is based on the iterative regularization method. Indeed, the three problems: direct, in variation and adjoint, classically associated with this method, are solved by the finite element method in a two-dimensional axisymmetric domain. The originality of this work is to treat an experimental estimation of a front motion using a model with a geometry including only the solid phase. In this model, the evolution of this solid domain during the fusion is set with the ALE moving mesh method (Arbitrary Lagrangian Eulerian). The numerical developments are realized with the commercial code Comsol Multiphysics® coupled with the software Matlab®. The estimation method has been validated in a previous work using theoretical data ([1]). The experimental data, used here for this identification are, temperatures measured by thermocouples in the solid phase, the temporal evolution of the melt pool boundary observed at the surface by a fast camera and the maximal dimensions of the melted zone measured on macrographs. These experimental data are also compared with numerical results obtained from a heat and fluid flow model taking into account surface tension effects, Lorentz forces and the deformation of the melt pool surface under arc pressure
Using Taguchi method to optimize welding pool of dissimilar laser welded components
In the present work CO2 continuous laser welding process was successfully applied and optimized for joining a dissimilar AISI 316 stainless steel and AISI 1009 low carbon steel plates. Laser power, welding speed, and defocusing distance combinations were carefully selected with the objective of producing welded joint with complete penetration, minimum fusion zone size and acceptable welding profile. Fusion zone area and shape of dissimilar austenitic stainless steel with ferritic low carbon steel were evaluated as a function of the selected laser welding parameters. Taguchi approach was used as statistical design of experiment (DOE) technique for optimizing the selected welding parameters in terms of minimizing the fusion zone. Mathematical models were developed to describe the influence of the selected parameters on the fusion zone area and shape, to predict its value within the limits of the variables being studied. The result indicates that the developed models can predict the responses satisfactorily
Artificial neural network prediction of weld distortion rectification using a travelling induction coil
An experimental investigation has been carried out to determine the applicability of an induction heating process with a travelling induction coil for the rectification of angular welding distortion. The results obtained from experimentation have been used to create artificial neural network models with the ability to predict the welding induced distortion and the distortion rectification achieved using a travelling induction coil. The experimental results have shown the ability to reduce the angular distortion for 8 mm and 10 mm thick DH36 steel plate and effectively eliminate the distortion on 6 mm thick plate. Results for 6 mm plate also show the existence of a critical induction coil travel speed at which maximum corrective bending occurs. Artificial neural networks have demonstrated the ability to predict the final distortion of the plate after both welding and induction heating. The models have also been used as a tool to determine the optimum speed to minimise the resulting distortion of steel plate after being subjected to both welding and induction heating processes
Deep drawing simulations of Tailored Blanks and experimental verification
Tailored Blanks are increasingly used in the automotive industry.\ud
A combination of different materials, thickness, and coatings can be welded\ud
together to form a blank for stamping car body panels. The main advantage\ud
of using Tailored Blanks is to have specific characteristics at particular parts\ud
of the blank in order to reduce the material weight and costs.\ud
To investigate the behaviour of Tailored Blanks during deep drawing, the\ud
finite element code DiekA is used. In this paper, simulations of the deep\ud
drawing of two products using Tailored Blanks are discussed. For\ud
verification, the two products are stamped to gain experimental information.\ud
The correlation between the experimental results and the simulation results\ud
appears to be satisfactory
Energy-Based Optimal Ranking of the Interior Modes for Reduced-Order Models under Periodic Excitation
This paper introduces a novel method for ranking and selecting the interior modes to be retained in the Craig-Bampton model reduction, in the case of linear vibrating systems under periodic excitation. The aim of the method is to provide an effective ranking of such modes and hence an optimal sequence according to which the interior modes should be progressively included to achieve a desired accuracy of the reduced-order model at the frequencies of interest, while keeping model dimensions to a minimum. An energy-based ranking (EBR) method is proposed, which exploits analytical coefficients to evaluate the contribution of each interior mode to the forced response of the full-order system. The application of the method to two representative systems is discussed: an ultrasonic horn and a vibratory feeder. The results show that the EBR method provides a very effective ranking of the most important interior modes and that it outperforms other state-of-the-art benchmark techniques
Research at the Institute of electrotechnology in the field of induction heating
The paper informs generally about the activities at the Institute of Electrotechnology in Hannover, Germany in the fields of education and research in Electrotechnology. Several actual research projects are described in detail in the field of induction heating. A second paper written by Baake and Spitans gives an overview about the activities at the institute in induction melting
Mechanical Properties Characterization of Welded Automotive Steels
Among the various welding technologies, resistance spot welding (RSW) and laser beam welding (LBW) play a significant role as joining methods for the automobile industry. The application of RSW and LBW for the automotive body alters the microstructure in the welded areas. It is necessary to identify the mechanical properties of the welded material to be able to make a reliable statement about the material behavior and the strength of welded components. This study develops a method by which to determine the mechanical properties for the weldment of RSW and LBW for two dual phase (DP) steels, DP600 and DP1000, which are commonly used for the automotive bodies. The mechanical properties of the resistance spot weldment were obtained by performing tensile tests on the notched tensile specimen to cause an elongation of the notched and welded area in order to investigate its properties. In order to determine the mechanical properties of the laser beam weldment, indentation tests were performed on the welded material to calculate its force-penetration depth-curve. Inverse numerical simulation was used to simulate the indentation tests to determine and verify the parameters of a nonlinear isotropic material model for the weldment of LBW. Furthermore, using this method, the parameters for the material model of RSW were verified. The material parameters and microstructure of the weldment of RSW and LBW are compared and discussed. The results show that the novel method introduced in this work is a valid approach to determine the mechanical properties of welded high-strength steel structures. In addition, it can be seen that LBW and RSW lead to a reduction in ductility and an increase in the amount of yield and tensile strength of both DP600 and DP1000
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