Abstract
GMA welding is widely used in many different fields such as automotive, shipbuilding and plant industry and its demand is growing day by day because of its high productivity and quality with cost reduction in manufacturing process. Nevertheless, the studies have been reported just a few cases so far due to its difficulties in expressions for the complexity of physical phenomena and in the derivation of the mathematical models. In this research, its complex numerical models including three-dimensional heat flux, arc pressure and electromagnetic force are newly suggested and its validation is proved through the comparison between the experimental and simulation results. Basically, the arc heat flux, arc pressure and Marangoni flow are employed as the boundary conditions. And electromagnetic force and buoyancy are realized as body terms. The governing equations such as the continuity, momentum, VOF and energy equations are adopted as usual simulations. It is, however, that only these equations cannot fulfill all requirements to investigate the behavior of the weld pool in GMA welding. To compensate the insufficient, three-dimensional mathematical model and coordinate transform of arc are newly suggested to reflect the twisted torch angle and arc effective radius change according to the distance from electrode tip. Suggested analysis model is verified through comparison to lap joint fillet GMAW experiment of steel sheets for automotive industry and it shows successful correspondence.
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Abbreviations
- B:
-
magnetic flux density
- CA :
-
concentration coefficent of arc
- Cp :
-
specific heat at constant pressure
- F:
-
volume fraction occupied by fluid
- Fx :
-
force in the x direction
- Fy :
-
force in the y direction
- Fz :
-
force in the z direction
- gz :
-
gravitational acceleration in the z direction
- h :
-
enthalpy
- h A :
-
convection coefficient
- I:
-
welding current
- J :
-
current density
- J z :
-
current density in the z dirction
- K:
-
thermal conductivity
- L f :
-
latent heat of fusion
- n:
-
normal component
- P:
-
pressure
- P A :
-
arc pressure
- qA :
-
heat input by arc
- qd :
-
heat input by droplet
- rA :
-
effective radius of arc
- rd :
-
droplet radius
- Rx :
-
coordinate transformation matrix for x axis
- Ry :
-
coordinate transformation matrix for y axis
- T:
-
temperature
- Td :
-
droplet temperature
- t:
-
time
- Tl :
-
liquidus temperature
- Ts :
-
solidus temperature
- T∞ :
-
ambient temperature
- V:
-
welding voltage
- V⃗:
-
velocity vector
- x, y, z:
-
coordinate index in local coordinate system
- x′, y′, z′:
-
coordinate index in global coordinate system
- β :
-
volume thermal expansion coefficient
- γ :
-
surface tension
- ε s :
-
emissivity
- η A :
-
heat input efficiency by arc
- η d :
-
heat input efficiency by droplet transfer
- θ :
-
travel angle for torch
- μ :
-
viscosity
- μ m :
-
magnetic permeability of metal
- μ 0 :
-
magnetic permeability in vaccum
- ν :
-
dynamic viscosity
- π :
-
circular constant
- ρ :
-
density
- σ :
-
normal stress
- σ s :
-
Stefan-Boltzmann constant
- τ :
-
shear stress,surface tangential direction
- φ :
-
work angle for torch
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Jeong, H., Park, K., Baek, S. et al. Three-Dimensional Numerical Analysis of Weld Pool in GMAW with Fillet Joint. Int. J. Precis. Eng. Manuf. 19, 1171–1177 (2018). https://doi.org/10.1007/s12541-018-0138-4
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DOI: https://doi.org/10.1007/s12541-018-0138-4