Finite Element Modelling, Predictive Modelling and Optimization of Metal Inert Gas, Tungsten Inert Gas and Friction Stir Welding Processes: A Comprehensive Review

Kalita, Kanak; Burande, D. H.; Ghadai, Ranjan Kumar; Chakraborty, Shankar

doi:10.1007/s11831-022-09797-6

Cited by 11 publications

(7 citation statements)

References 204 publications

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“…This discrepancy will lead to generation of imprecise results, during the evaluation process of GRG. As a result, there prevails a need for normalizing the actual data [23,24]. The contribution percentage of each and every response can be determined by employing PCA (i.e., principal component analysis) and then used in GRG based calculation.…”

Section: Gra-pcamentioning

confidence: 99%

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Optimization of parameters and formulation of numerical model employing GRA–PCA and RSM approach for friction stir welded Ti–6Al–4V alloy joints

Babu S D

et al. 2024

Mater. Res. Express

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In this work, an endeavor was made to determine the impact of the tool’s shoulder diameter, pin profile, rotational and traverse speeds on the mechanical properties of the friction stir welded namely Ti–6Al–4V alloy joints. A total of 21 experiments were carried out based on the central composite design (CCD) concept of response surface methodology (RSM). A quadratic regression based numerical model was formulated to ascertain the relationship amidst the parameters of FSW process and the mechanical properties of the fabricated Ti alloy joints. Analysis of variance (ANOVA) was employed to confirm the importance of parameters and their interactive impacts. Optimized process parameter combinations were ascertained by grey relation based analysis (GRA) was coupled together with principal component analysis (PCA), a hybrid based approach. Single score of GRG based response was determined and GRG scores were ranked for all experiments. 1st rank was attained by the experiment no. 20 possessing a GRG score of 2.9989. Optimized values of 25mm shoulder diameter having a taper cylindrical pin geometry employed at a tool traverse speed of 40 mm/min, rotational speed of 1400 rpm resulted in the generation of flaw free Ti alloy joint possessing a largest tensile strength of 809.8 MPa, yield strength of 778.7 MPa and percentage of elongation of 6.9%. SEM based fractography ofTi alloy joint specimens announced that taper cylindrical pin geometry along with 25m shoulder diameter of employed tool have an inevitable part in generating frictional heat in ideal volumes and a perfect stirring action during FSW process.

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Section: Gra-pcamentioning

confidence: 99%

“…These secondary phase precipitates encounter fracture in foremost manner during tensile test. This was mainly due to the fact that these secondary phase precipitates promote the formation of micro dents and deep hole depressions in the TMIZ, leading to the failure of the joint in the TMIZ [18,23,32].…”

Section: Inferences From Tensile Fractographymentioning

confidence: 99%

Optimization of parameters and formulation of numerical model employing GRA–PCA and RSM approach for friction stir welded Ti–6Al–4V alloy joints

Babu S D

et al. 2024

Mater. Res. Express

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“…Llevar a cabo un proceso de modelado y simulación por FEM da pauta a dar pasos dentro de la optimización de estos mismos con sistemas computacionales que son empleados en diferentes áreas de la ingeniería e industria por lo que es de gran interés el formular líneas de investigación enfocadas con este tipo de herramientas para evaluar, en este caso, una junta mecánica, como cualquier otro espécimen de prototipaje, se concuerda con [37] y [38], identificando que los FEM tienen gran coincidencia con procesos experimentales y que deben utilizarse de la mano para reducir los errores en los resultados que se encuentran dentro del 10%. En referencia a [39], la estructura de una junta puede evaluarse con FEM en subestructuras para focalizar las secciones de mayor incidencia hacia la falla, lo cual representa una tendencia a utilizar el este caso de estudio y orientar la línea de investigación de acuerdo con los resultados obtenidos en las simulaciones de este trabajo de investigación.…”

Section: Estanqueidadunclassified

Control del mallado con FEM para caracterizar una junta mecánica en aplicaciones de investigación y prototipaje

González-Sosa,

Ávila-Soler

2024

Rev. Ci. Tec.

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Una de las características clave de los sellos mecánicos es lograr una estanqueidad efectiva entre dos piezas mecánicas para evitar el desplazamiento y las fugas de refrigerante en aplicaciones industriales. Actualmente la mayoría de estos elementos se producen utilizando neopreno, cartón comprimido, papel alquitranado, grafito laminado, por lo que buscamos producirlos utilizando materiales ABS y PLA. Para el diseño se utilizó software CAD con licencia educativa destinada a educadores e investigadores, posteriormente se realiza un análisis de elementos finitos según las especificaciones del producto. En este sentido, se ha identificado la importancia del FEM como herramienta de evaluación en el contexto de esta tendencia de utilizar tecnologías innovadoras para la investigación. Como parte de los resultados, los datos obtenidos permiten seleccionar tanto las variables como las propiedades físicas de la biela y pueden ser utilizados para desarrollar proyectos y estudios de esta naturaleza aplicables en casos de estudio relacionados con la Ingeniería mecánica, mecatrónica, industrial y electrónica. Finalmente, las variables Factor de Seguridad (FS), Von Mises Stress (VM) y YZ Stress, se analizan después de la simulación mediante FEM, proporcionando un rango de valores para su uso en aplicaciones de ingeniería con diferentes técnicas en las que se utilizan bielas, FS [ 0,55, 12,26], VM [1,63, 36,45], YZ [-1,36, 10,13]. En cuanto a los demás resultados presentados en este estudio, el coeficiente de correlación se utiliza como parte estadística con gráficos para evaluar la simulación, la dependencia de variables y parámetros relevantes para el estudio de caso, por lo que se observó una fuerte relación entre las variables; esfuerzo plano, deformación, desplazamiento y el esfuerzo de Von Mises, cuyos valores oscilan entre 0,87 y 0,99, mostrando una fuerte relación entre estas variables y, para las demás, se debe considerar mejorar la relación y aumentar el coeficiente.

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“…Therefore, studying and monitoring the variables that influence weld quality by applying different experimental, numerical, and analytical tools is essential. A comprehensive review was carried out by Kalita et al [27] on the finite element model (FEM), predictive modeling, and optimization of inert metal gas (MIG), tungsten inert gas (TIG), and FSW. The authors concluded that the design of experiments (DOE) is an effective technique that reduces experimental trials and derives empirical prediction equations [27].…”

Section: Introductionmentioning

confidence: 99%

“…The review focused on methods used for tool design, pre-and post-heat treatments, and grooves incorporated for deploying reinforcement particles that affect the joint properties, which are discussed in detail [1,21]. The detailed review report highlighted the importance of optimizing parameters that could alter the microstructure in attaining superplasticity in alloys [1,21,27,29]. The modification to the FSW technique (i.e., welding underwater) to minimize the peak temperature, which adversely affects the properties of the welded joints, is discussed by Mofid et al [30].…”

Section: Introductionmentioning

confidence: 99%

A Review of Optimization and Measurement Techniques of the Friction Stir Welding (FSW) Process

Prabhakar,

Korgal,

Shettigar

et al. 2023

JMMP

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This review reports on the influencing parameters on the joining parts quality of tools and techniques applied for conducting process analysis and optimizing the friction stir welding process (FSW). The important FSW parameters affecting the joint quality are the rotational speed, tilt angle, traverse speed, axial force, and tool profile geometry. Data were collected corresponding to different processing materials and their process outcomes were analyzed using different experimental techniques. The optimization techniques were analyzed, highlighting their potential advantages and limitations. Process measurement techniques enable feedback collection during the process using sensors (force, torque, power, and temperature data) integrated with FSW machines. The use of signal processing coupled with artificial intelligence and machine learning algorithms produced better weld quality was discussed.

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Finite Element Modelling, Predictive Modelling and Optimization of Metal Inert Gas, Tungsten Inert Gas and Friction Stir Welding Processes: A Comprehensive Review

Cited by 11 publications

References 204 publications

Optimization of parameters and formulation of numerical model employing GRA–PCA and RSM approach for friction stir welded Ti–6Al–4V alloy joints

Optimization of parameters and formulation of numerical model employing GRA–PCA and RSM approach for friction stir welded Ti–6Al–4V alloy joints

Control del mallado con FEM para caracterizar una junta mecánica en aplicaciones de investigación y prototipaje

A Review of Optimization and Measurement Techniques of the Friction Stir Welding (FSW) Process

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