Design of a wire measurement system for dynamic feeding TIG welding using instantaneous angular speed

Silva, Régis Henrique Gonçalves e; Paes, Luiz Eduardo dos Santos; Sousa, Gustavo Luis de; Marques, Cleber; Viviani, Alberto Bonamigo; Schwedersky, Mateus Barancelli; Pinto, Tiago

doi:10.1007/s00170-018-3026-2

Cited by 14 publications

(2 citation statements)

References 25 publications

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“…Indeed, the LBW can replace conventional welding techniques because of its many advantages [2]. Besides, LBW presents excellent precision and efficiency characteristics compared to traditional welding methods such as gas tungsten arc welding (GTAW) [3,4] and gas metal arc welding (GMAW) [5]. It permits the welding of complex geometries and dissimilar materials [2], aside from assuring greater levels of product quality [6].…”

Section: Introductionmentioning

confidence: 99%

A Thermal Analysis of LASER Beam Welding Using Statistical Approaches

et al. 2023

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Implementing input parameters that match the experimental weld shape is challenging in LASER beam welding (LBW) simulation because the computed heat input and spot for temperature acquisition strongly affect the outcomes. Therefore, this study focuses on investigating the autogenous LBW of AISI 1020 using a three-dimensional heat transfer model that assumes a modified Gaussian heat flux distribution depending on LASER power (Qw), radius (R), and penetration (hp). The influence of such variables on the simulated weld bead was assessed through analysis of variance (ANOVA). The ANOVA returns reliable results as long as the data is normally distributed. The input radius exerts the most prominent influence. Taguchi’s design defined the studied data reducing about 65% of the simulations compared to a full factorial design. The optimum values to match the computed outcomes to lab-controlled experiments were 2400 W for power (80% efficiency), 0.50 mm for radius, and 1.64 mm for penetration. Moreover, the experimental errors regarding thermocouples positioning were corrected using linear interpolation. A parallel computing algorithm to obtain the temperature field reduces computational costs and may be applied in real-world scenarios to determine parameters that achieve the expected joint quality. The proposed methodology could reduce the required time to optimize a welding process, saving development and experimental costs.

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Section: Introductionmentioning

confidence: 99%

A Thermal Analysis of LASER Beam Welding Using Statistical Approaches

et al. 2023

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“…Its measurement method is non-intrusive, which reduces interference in the system operating conditions. Its applications involve the diagnosis of faults in engines [9] and gear transmissions [10][11][12], the quantification of fan and turbine blade faults [13], the measurement of vibrations in wire-feed welding systems [14], the identification of faults in rolling bearings [15][16][17], and monitoring the condition of CNC machine tools and motors [18]. Alhashimi et al [19] obtained the waveform characteristics of centrifugal pumps' IAS signals under different experimental conditions and analyzed the merits of their use in monitoring the status of a cavitation fault.…”

Section: Introductionmentioning

confidence: 99%

A Hydraulic Axial Piston Pump Fault Diagnosis Based on Instantaneous Angular Speed under Non-Stationary Conditions

Liu,

Meng,

Zhou

et al. 2023

Lubricants

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Due to the intense noise interference in hydraulic systems, it is extremely difficult to detect component faults through vibration signals. Diagnostic performance is also constrained by highly time-varying and non-stationary operating conditions. This study proposes to use instantaneous angular speed (IAS) signals that are both operational and state parameters as sources of information. Firstly, the instantaneous angular speed fluctuation (IASF) of a piston pump is analyzed theoretically, and it is concluded that its fluctuating components contain the health status information of the components. The IASF can then be obtained by subtracting the speed trend term from IAS signals obtained via a magneto-electric speed sensor. A synchro-extraction of the normal S transform (SNST) is proposed to process it via line-pass filtering. Finally, the filtered and reconstructed IASF signal is utilized to draw a two-dimensional polar coordinate map online. A non-stationary-condition test is carried out on the test platform to monitor the morphological characteristics of the valve plate under normal, slight, and severe wear conditions. The polar plot shows significant increases in speed fluctuations and oscillation times within a range from 180° to 270°. The relevant research results reflect that the IAS signal can provide a new method for monitoring the operating status of and conducting fault diagnoses for hydraulic equipment.

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Sensitivity analysis and multi-objective optimization of tungsten inert gas (TIG) welding based on numerical simulation

Paes

Andrade

Lobato

et al. 2022

Int J Adv Manuf Technol

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In welding processes, many factors contribute in achieving a required quality of the welds. Those factors are numerous and they may interact with each other, affecting response parameters such as welding penetration and the Heat Affected Zone (HAZ) size. Some factors are more important while the influence of others is negligible.To find an optimum factor combination in order to maximize penetration and minimize the HAZ is not an easy task. This contribution is aimed to evaluate the influence of welding energy (E) versus the influence of current (I) and welding speed (Vw) on the penetration and HAZ volume in the autogenous Tungsten Inert Gas (TIG) welding process. For this purpose, phenomenological and empirical models are proposed. The first considers an in-house Finite Volume numerical model, and the second is based on Response Surface Method. A sensitivity analysis of the empirical model using two strategies is also performed. In addition, to determine the best-operating conditions, a multi-objective optimization problem is proposed and solved. The presented empirical models were found to provide good concordance in terms of coefficient of determination and p-value, indicating its significance. Each model (with one or more independent variables) represents detailed information about the physical process and can be used for optimization. The sensitivity analysis demonstrates that the current affects penetration and HAZ volume much stronger than the welding speed does. Physically, this is due to the fact current has linear (arc coupling) and non-linear (Joule effect and pressure gradient) influence, and the welding speed contributes linearly, modulating the heat conduction. Finally, it was demonstrated a compromise between the penetration and the HAZ volume by addressing multi-objective optimization. In this context, point C (I = 250 A; VW= 24.8 cm/min) of the Pareto curve is the optimal option for operation since it provides a lower relative HAZ volume while keeping the same penetration and higher productivity (welding speed).

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Design of a wire measurement system for dynamic feeding TIG welding using instantaneous angular speed

Cited by 14 publications

References 25 publications

A Thermal Analysis of LASER Beam Welding Using Statistical Approaches

A Thermal Analysis of LASER Beam Welding Using Statistical Approaches

A Hydraulic Axial Piston Pump Fault Diagnosis Based on Instantaneous Angular Speed under Non-Stationary Conditions

Sensitivity analysis and multi-objective optimization of tungsten inert gas (TIG) welding based on numerical simulation

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