A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications

Abstract

During multidisciplinary design of welded aircraft components, designs are principally optimized upon component performance, employing well-established modelling and simulation techniques. On the contrary, because of the complexity of modelling welding process phenomena, much of the welding experimentation relies on physical testing, which means welding producibility aspects are considered after the design has already been established. In addition, welding optimization research mainly focuses on welding process parameters, overlooking the potential impact of product design. As a consequence, redesign loops and welding rework increases product cost. To solve these problems, in this article, a novel method that combines the benefits of design of experiments (DOE) techniques with welding simulation is presented. The aim of the virtual design of experiments method is to model and optimize the effect of design and welding parameters interactions early in the design process. The method is explained through a case study, in which weld bead penetration and distortion are quality responses to optimize. First, a small number of physical welds are conducted to develop and tune the welding simulation. From this activity, a new combined heat source model is presented. Thereafter, the DOE technique optimal design is employed to design an experimental matrix that enables the conjointly incorporation of design and welding parameters. Welding simulations are then run and a response function is obtained. With virtual experiments, a large number of design and welding parameter combinations can be tested in a short time. In conclusion, the creation of a meta-model allows for performing welding producibility optimization and robustness analyses during early design phases of aircraft components.

Constraint Replacement-Based Design for Additive Manufacturing of Satellite Components: Ensuring Design Manufacturability through Tailored Test Artefacts

“…To ensure reliable, repeatable, and structured results, implementing techniques, such as DOEs [44], are considered for a future extension of the presented method. The use of these techniques has proven to be a reliable and efficient strategy for optimizing testing activities in the aerospace sector [50]. Currently, research on how process parameters impact product quality is scarce [51].…”

Multiphysics Modeling, Sensitivity Analysis, and Optical Performance Optimization for Optical Laser Head in Additive Manufacturing

“…Based on the fitted mathematical model, optimal responses were predicted using the optimization technique and validated with experiments. Now, RSM-based DoCE is also used in the simulation-based optimal product and process design in many industrial applications [14][15][16].…”

Automated and interactive evaluation of welding producibility in an multidisciplinary design optimization environment for aircraft components

“…Modeling of cracks and weld bead geometry formation are still in the research stages [35,36]. Recent research studies also cover simulating the effect of welding set-up changes, such as for example different laser welding beam incident angles [10,37].…”

“…The research work published in this paper builds upon a seven-year academic-industrial collaboration aimed at developing methods and tools with which to predict product quality after welding, in addition to controlling welding -manufacturing variation and defects during early design phases. In this paper, the results from a number of previous research publications have been incorporated, see [8][9][10][11].…”