Distortion minimization of laser beam welded components by the use of finite element simulation and Artificial Intelligence

Belitzki, A.; Stadter, Christian; Zaeh, Michael F.

doi:10.1016/j.cirpj.2019.10.001

Cited by 8 publications

(4 citation statements)

References 8 publications

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“…Belitzki et al [47], in his experience, developed a method to minimize distortions caused by laser beam welding. This method consisted of using a meta-model by means of an artificial neural network to predict local distortions in a complex structure, depending on several welding parameters.…”

Section: Position Experimental Large Distortion Theory Small Distortimentioning

confidence: 99%

Comparison of Finite Element Methods in Fusion Welding Processes—A Review

Marques

Silva

Péreira

2020

Metals

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Currently, welding processes have become one of the most used methods for joining materials in all kinds of industries, thanks to properties such as high speed and high tensile strength. However, despite these advantages, this type of connection method has some drawbacks, for example, residual stress and structural distortion, mainly due to the process thermal cycles. Structural distortion is one of the major concerns of industrial joining practice. In order to decrease distortion, the variation of welding sequence, direction, and clamping conditions, have been applied through several years, by trial and error tests. However, numerical simulation enables virtual examination of the welding, mainly due to the progress on the numerical methods, which stimulated the research on welding simulation models. These models can cover a wide spectrum of physical and thermal processes occurring during, and after welding. The aim of this paper is to provide wider information about types of finite element method (FEM) in fusion welding processes and to demonstrate the accuracy of FEM models results compared to experimental.

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Section: Position Experimental Large Distortion Theory Small Distortimentioning

confidence: 99%

Comparison of Finite Element Methods in Fusion Welding Processes—A Review

Marques

Silva

Péreira

2020

Metals

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“…Belhadj et al developed a numerical model for the fusion zone of laser welded magnesium alloys [22]. Belitzki et al developed a numerical model to predict the welding deformation of laser-welded joints [23]. They also combined numerical simulation with artificial intelligence to obtain an optimized welding sequence, which proved to be beneficial to the reduction of welding deformations.…”

Section: Introductionmentioning

confidence: 99%

Effect of Welding Gap of Thin Plate Butt Welds on Inherent Strain and Welding Deformation of a Large Complex Box Structure

Zhang,

Peng,

Yang

et al. 2024

Materials

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In this study, an effective numerical model was developed for the calculation of the deformation of laser-welded 3 mm 304L stainless steel plates with different gaps (0.2 mm, 0.5 mm, and 1.0 mm). The welding deformation would become larger when the welding gaps increased, and the largest deformation values along the Z direction, of 4 mm, were produced when the gap value was 1.0 mm. A larger plastic strain region was generated in the location near the weld seam, since higher plastic deformation had occurred. In addition, the tensile stress model was also applied at the plastic strain zone and demonstrated that a larger welding gap led to a wider residual stress area. Based on the above results, inherent deformations for butt and corner joints were calculated according to inherent strain theory, and the welding formation for the complex structure was calculated with different gaps. The numerical results demonstrated that a larger deformation was also produced with a larger welding gap and that it could reach the highest value of 10.1 mm. This proves that a smaller welding gap should be adopted during the laser welding of complex structures to avoid excessive welding deformation.

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“…Such studies focusing on stresses and distortions can be widely found for conventional welding applications. Biswas et al (2011) investigated the influence of the welding sequence of stiffeners on the distortion of a plate, while Belitzki et al (2019) used simulation and artificial intelligence to optimize the welding sequence of a frame structure. In addition, authors of other studies have confirmed that the welding sequence has a significant effect on the part distortion (Fu et al , 2016; Tsai et al , 1999).…”

Section: Introductionmentioning

confidence: 99%

Experimental and simulative investigation of welding sequences on thermally induced distortions in wire arc additive manufacturing

Zhao

Wimmer

Zaeh

2023

RPJ

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Purpose The purpose of this paper is to demonstrate the impact of the welding sequence on the substrate plate distortion during the wire and arc additive manufacturing (WAAM) process. This paper also aims to show the capability of finite element simulations in the prediction of those thermally induced distortions. Design/methodology/approach An experiment was conducted in which solid aluminum blocks were manufactured using two different welding sequences. The distortion of the substrates was measured at predefined positions and converted into bending and torsion values. Subsequently, a weakly coupled thermo-mechanical finite element model was created using the Abaqus simulation software. The model was calibrated and validated with data gathered from the experiments. Findings The results of this paper showed that the welding sequence of a part significantly affects the formation of thermally induced distortions of the final part. The calibrated simulation model was able to capture the different distortion behavior attributed to the welding sequences. Originality/value Within this work, a simulation model was developed capable of predicting the distortion of WAAM parts in advance. The findings of this paper can be used to improve the design of WAAM welding sequences while avoiding high experimental efforts.

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Distortion minimization of laser beam welded components by the use of finite element simulation and Artificial Intelligence

Cited by 8 publications

References 8 publications

Comparison of Finite Element Methods in Fusion Welding Processes—A Review

Comparison of Finite Element Methods in Fusion Welding Processes—A Review

Effect of Welding Gap of Thin Plate Butt Welds on Inherent Strain and Welding Deformation of a Large Complex Box Structure

Experimental and simulative investigation of welding sequences on thermally induced distortions in wire arc additive manufacturing

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