Numerical simulation of slag forming process during submerged arc welding using DEM-ISPH hybrid method

Komen, Hisaya; Shigeta, Masaya; Tanaka, Manabu; Nakatani, Mitsuyoshi; Abe, Yohei

doi:10.1007/s40194-018-0655-x

Cited by 18 publications

(6 citation statements)

References 14 publications

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“…We have applied this incompressible SPH method to the thermofluid simulations of molten metal flows in several kinds of arc welding processes such as GTA weding, 133,134) GMA welding, [135][136][137][138][139] SA welding, 140,141) and Flux-Cored Arc (FCA) welding. 142) Because this incompressible SPH method offers high adaptability for other types of metal processing, it has also revealed the molten metal formation processes with convective and diffusive heat transports during dissimilar Resistance Spot (RS) welding 143,144) and Electroslag (ES) welding 145) collaborating with the experiments, 146,147) and dross formation during gas cutting.…”

Section: Sph Representationmentioning

confidence: 99%

Progress of computational plasma fluid mechanics

Shigeta

2023

Jpn. J. Appl. Phys.

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This article reviews and discusses the recent progresses of studies with the concept of “Computational plasma fluid mechanics”. Computational demonstrations show that the inhouse simulation codes such as PLASTIPC (PLasma All-Speed Turbulence with Implicit Pressure Code) have captured hydrodynamic instabilities and reproduced flow dynamics in thermal plasma – nonionized gas coexisting systems. A unique method has made it feasible to study collective growth of binary alloy nanoparticles by numerical analysis. SPH (Smoothed Particle Hydrodynamics) method with incompressibility modification has achieved complex behaviors of molten metal involving phase change, flow, heat transport, material mixing, and large deformation during arc welding. It is essential to study thermal plasma processes as comprehensive fluid systems in which hot plasma, cold nonionized gas, and materials coexist. The viewpoint and approaches of fluid mechanics as well as plasma physics are indispensable. Computational study will play a more important role in giving us new and deeper insights.

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Section: Sph Representationmentioning

confidence: 99%

Progress of computational plasma fluid mechanics

Shigeta

2023

Jpn. J. Appl. Phys.

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“…The discrete element method (DEM) is a computer simulation method that can model the behaviors of such powders (14)(15)(16)(17)(18)(19)(20)(21)(22)(23)(24)(25) , as it numerically analyzes the motion of each particle according to Newton's equation of motion and Euler's equation of motion by calculating the viscoelastic and frictional forces acting between the particles. This method has been developed in various studies of phenomena relevant to a massive number of particles, such as sediment flow, ball milling of powders, silo filling, powder mixing (72) , and the behavior of slag particles in submerged arc welding (73) . The DEM technique has also been applied to the analysis and optimization of powder layer formation in the PBF process (21)(22)(23) .…”

Section: Powder Flow Processmentioning

confidence: 99%

Digital Twin Science of Metal Powder Bed Fusion Additive Manufacturing: A Selective Review of Simulations for Integrated Computational Materials Engineering and Science

Okugawa

2022

ISIJ Int.

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A digital twin (DT) is a cyberspace replica of a system, such as manufacturing equipment. A DT consists of statistical models and computer simulations of physical phenomena occurring in the system. The modeling is adjusted to the system based on signals from sensors attached to the system and their temporal changes. In general, a DT is utilized to (i) predict phenomena occurring in the system, (ii) optimize control parameters, and (iii) estimate part replacement schedules. We propose to use a DT to elucidate the unique solidification phenomena occurring in a type of metal 3D printing (i.e., additive manufacturing: AM) process. Thus, we propose that applications of DT that obtain scientific data be referred to as "digital twin science (DTS)." This paper first reviews the fundamental of the AM process, particularly powder bed fusion (PBF) and relevant computer simulations, and then studies on computer simulations conducted to elucidate the relationship between the extreme conditions characteristic of the PBF process and solidification microstructures. The findings achieved by the DTS approach indicate that the combination of experimental and simulation data aid the future development of techniques to obtain required microstructures exhibiting desired properties.

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“…The calculation for physical quantities of the arc plasma assumes a two-dimensional axisymmetric condition and a steady state. Physical quantities of the arc plasma are obtained by a calculation with a grid-based method 12) using the initial shape of the wire. Therefore, a heat source distribution of the arc plasma does not change during a computation with the wire shape deformation.…”

Section: Computational Conditionsmentioning

confidence: 99%

Numerical Simulation of Droplet Transfer with TiO2 Flux Column During Flux Cored Arc Welding by 3D Smoothed Particle Hydrodynamics Method

Ueno

Komen

Shigeta

et al. 2020

QUARTERLY JOURNAL OF THE JAPAN WELDING SOCIETY

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A molten metal droplet transfer processes were simulated by a numerical model using a three-dimensional smoothed particle hydrodynamics method in order to clarify the flux column formation mechanism at the tip of a wire during a flux cored arc welding process. This study focuses on the flux cored arc welding with TiO2 based wire. As a result, although the average droplet size obtained by the computation was larger than that by the experiment, the average length of the flux column obtained by the computation showed agreement with that by the experiment, which supports supported validity of this computational model. Moreover, the melting rate of the metal-pipe around flux was higher than flux. The flux column was formed at the tip of the wire. The simulations with different values of a specific heat and a thermal conductivity were performed to investigate the effect of the heat conduction in the wire on the flux column formation. The unmelted flux column was formed at the tip of the wire when the specific heat of the flux component was smaller and the thermal conductivity was higher than those of TiO2. The result indicated that the heat conduction in flux played an important role in the flux column formation during flux cored arc welding.

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Numerical simulation of slag forming process during submerged arc welding using DEM-ISPH hybrid method

Cited by 18 publications

References 14 publications

Progress of computational plasma fluid mechanics

Progress of computational plasma fluid mechanics

Digital Twin Science of Metal Powder Bed Fusion Additive Manufacturing: A Selective Review of Simulations for Integrated Computational Materials Engineering and Science

Numerical Simulation of Droplet Transfer with TiO2 Flux Column During Flux Cored Arc Welding by 3D Smoothed Particle Hydrodynamics Method

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