Distortion simulation of gas metal arc welding (GMAW) processes for automotive body assembly

Cai, Wayne; Saez, Miguel; Spicer, Patrick T.; Chakraborty, Debejyo; Skurkis, Richard; Carlson, Blair E.; Okigami, Fernando; Robertson, J. W.

doi:10.1007/s40194-022-01369-3

Cited by 4 publications

(3 citation statements)

References 23 publications

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“…Comparison between the theoretical predictions of the proposed model with the theoretical and experimental results published in Cai et al 21 with the intensity of clamping force: (a) 370.6 N and (b) 631.5 N.…”

Section: Resultsmentioning

confidence: 88%

“…They performed modal analysis to validate the predictions of their suggested model. Cai et al 21 simulated the gas metal arc welding (GMAW) process to predict the workpiece deformation in the fixture. The results of the numerical analysis were validated through experimental measurement of welding-induced physical parameters such as the clamping forces that were created due to the workpiece deformation.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Analysis of reaction forces in fixture locating points: An Analytical, numerical, and experimental study

Parvaz,

Hosseini

2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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Reaction forces are important parameters in fixture design. They are generated by the clamping forces and machining loads at the fixture locating points. These forces are used as input values in the determination of clamping forces, fixture stiffness, and workpiece deformation. In this paper, an analytical model based on the minimum norm principle was developed to calculate these forces. Numerical simulations and experimental tests were performed on a 3D polyhedral workpiece to validate the model. The simulations were conducted using Abaqus® software and the experimental tests used a fixture and a 3D polyhedral workpiece. The theoretical, numerical, and experimental results showed good agreement for the normal component of reaction forces. The maximum errors of 3.9% and 15% were observed between the theoretical predictions compared to the numerical and experimental results, respectively. The model was also used to study the effects of two influential parameters, the coefficient of friction and clamping force, on the reaction forces. The good agreement between the theoretical, numerical, and experimental results demonstrated the efficiency of the proposed model in the rapid calculation of reaction forces for fixturing 3D polyhedral workpieces.

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Section: Resultsmentioning

confidence: 88%

Section: Introductionmentioning

confidence: 99%

Analysis of reaction forces in fixture locating points: An Analytical, numerical, and experimental study

Parvaz,

Hosseini

2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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show abstract

“…Especially the welded joint of the welding structure is the weakest zone in the welding assembly, and the service behaviors and mechanical properties involving the ultimate strength are critically imperative for the thin-walled structure of the welding assembly [ 4 , 5 ]. Moreover, welding-induced deformation is a major concern in the assembly process caused by the non-uniform temperature field and rapid cooling, and the adverse effect of the welding deformation on the strength and fracture behaviors, ductile damage, assembly accuracy, stiffness distribution, vibration characteristics under different welding parameters, and service performance of welding structures does exist [ 6 , 7 , 8 , 9 , 10 ]. Therefore, the welding properties and performance of metal sheet parts are closely related to welding deformation.…”

Section: Introductionmentioning

confidence: 99%

Tensile Behaviors and Mechanical Property Analyses of T-Welded Joint for Thin-Walled Parts in Consideration of Different TIG Welding Currents Using Multiple Damage Models and Fracture Criterions: Numerical Simulation and Experiment Validation

Mao

Sun

et al. 2023

Materials

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In order to deeply investigate the tensile properties and fracture behaviors that are obtained by tensile tests of welded joints, constitutive and damage models are imperative for analyzing the tensile behaviors. In this work, the tensile tests are conducted on the T-welded joint specimens of aluminum alloy 6061-T6, which were cut from the T-welded joints of thin-walled parts under different welding currents of Tungsten Inert Gas Welding (TIGW). A modified Johnson-Cook (J-C) model based on the original J-C equation, Swift model, Voce model, and Hockett-Sherby (H-S) model, their linear combination model, and fracture failure model are constructed and applied to simulate tensile behaviors, combined with tensile test data. What is more, the finite element (FE) simulation of tension tests is executed with the VUMAT and VUSDFLD subroutines. Compared to those results simulated with different fracture criteria and tensile experiments, the tensile strength and yield strength of T-welded joint thin-walled parts under different welding currents were achieved, and their best mean errors were only about 1%. Furthermore, the accuracy of different fracture criteria is also evaluated by the correlation coefficient and mean squared error. The results show that the combination model can accurately predict the tensile properties and fracture behaviors of T-welded joints better than the single model, especially the results simulated with the Swift-H-S model and H-S-Voce model, which are in good agreement with tensile test results, which will provide an analysis foundation for enhancing the welding assembly quality and preventing fracture failure for complex thin-walled antenna structures.

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Numerical simulation on molten pool behavior of narrow gap gas tungsten arc welding

Zhu

Dong

Cai

et al. 2023

Int J Adv Manuf Technol

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Distortion simulation of gas metal arc welding (GMAW) processes for automotive body assembly

Cited by 4 publications

References 23 publications

Analysis of reaction forces in fixture locating points: An Analytical, numerical, and experimental study

Analysis of reaction forces in fixture locating points: An Analytical, numerical, and experimental study

Tensile Behaviors and Mechanical Property Analyses of T-Welded Joint for Thin-Walled Parts in Consideration of Different TIG Welding Currents Using Multiple Damage Models and Fracture Criterions: Numerical Simulation and Experiment Validation

Numerical simulation on molten pool behavior of narrow gap gas tungsten arc welding

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