Design of fixture for ultrasonic assisted gas tungsten arc welding using an integrated approach
-
Dhilip A
and
Anand K
Abstract
The welding fixture greatly impacts the weld quality matrixes. In this work, the welding fixture for ultrasonic-assisted gas tungsten arc welding to reduce the hot cracking behaviour in weldments was designed using the finite element analysis approach. A three-level, five-factor central composite design-based response surface methodology analysis was followed to vary the dimensions of the fixture for the modal and harmonic analysis of the fixture using Ansys software. The optimum fixture dimensions to achieve maximum displacement amplitude and minimum von-Mises stress have been optimized using a genetic algorithm approach. The model predictions for maximum displacement amplitude and minimum von-Mises stress were compared to the experimental findings at optimal conditions. A strong consensus between the model prediction by genetic algorithm and experimental findings indicates the correctness of the developed model.
Acknowledgments
The authors are thankful for the support provided by Management, PSG College of Technology, and SERB (Project No: SRG/2021/002283).
-
Research ethics: Not applicable.
-
Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission.
-
Competing interests: The authors state no conflict of interest.
-
Research funding: Science and Engineering Research Board, Govt. Of India, Project No: SRG/2021/002283.
-
Data availability: Not applicable.
References
1. Hosseini, S. A., Abdollah-Zadeh, A., Naffakh-Moosavy, H., Mehri, A. Elimination of hot cracking in the electron beam welding of AA2024-T351 by controlling the welding speed and heat input. J. Manuf. Process. 2019, 46, 147–158. https://doi.org/10.1016/j.jmapro.2019.09.003.Search in Google Scholar
2. Soysal, T., Kou, S. Predicting effect of filler metals on solidification cracking susceptibility of 2024 Al and 6061 Al. Sci. Technol. Weld. Join 2019, 24, 559–565. https://doi.org/10.1080/13621718.2019.1570683.Search in Google Scholar
3. Kolarik, L., Kovanda, K., Valova, M., Vondrous, P., Dunovsky, J. Weldability test of precipitation hardenable aluminium alloy en Aw 6082 T6. MM Sci. J. 2011, 2011, 243–247. https://doi.org/10.17973/mmsj.2011_07_201105.Search in Google Scholar
4. Pujari, K. S., Patil, D. V., Mewundi, G. Selection of GTAW process parameter and optimizing the weld pool geometry for AA 7075-T6 Aluminium alloy. Mater. Today: Proc. 2018, 5, 25045–25055. https://doi.org/10.1016/j.matpr.2018.10.305.Search in Google Scholar
5. Balasubramanian, K., Kesavan, D., Balusamy, V. Studies on the effect of vibration on hot cracking and grain size in AA 7075 aluminum alloy welding. Int. J. Eng. Sci. Technol. 2011, 3.Search in Google Scholar
6. Balasubramanian, K., Kesavan, D., Balusamy, V. Studies on the effect of vibration on hot cracking and grain size in AA 7075 aluminum alloy welding. Int. J. Eng. Sci. Technol. 2011, 3, 681–686.Search in Google Scholar
7. Dehmolaei, R., Shamanian, M., Kermanpur Effect of electromagnetic vibration on the unmixed zone formation in 25Cr-35Ni heat resistant steel/alloy 800 dissimilar welds. Mater. Charact. 2008, 59, 1814–1817. https://doi.org/10.1016/j.matchar.2008.05.003.Search in Google Scholar
8. Krajewski, A., Wlosinski, W., Chmielewski, T., Kolodziejczak, P. Ultrasonic-vibration assisted arc-welding of aluminum alloys. Bull. Pol. Acad. Sci. Tech. Sci. 2012, 60, 841–852. https://doi.org/10.2478/v10175-012-0098-2.Search in Google Scholar
9. Dai, W. L. Effects of high-intensity ultrasonic-wave emission on the weldability of aluminum alloy 7075-T6. Mater. Lett. 2003, 57, 2447–2454. https://doi.org/10.1016/S0167-577X(02)01262-4.Search in Google Scholar
10. Chen, Q., Lin, S., Yang, C., Fan, C., Ge, H. Grain fragmentation inultrasonic-assisted TIG weld of pure aluminum. Ultrason. Sonochem. 2017, 39, 403–413. https://doi.org/10.1016/j.ultsonch.2017.05.001.Search in Google Scholar PubMed
11. Jha, N. K. Design and analysis of welding fixture for elementary weld joints. CVR J. Sci. Technol. 2018, 15, 90–95. https://doi.org/10.32377/cvrjst1516.Search in Google Scholar
12. Brown, S. B., Song, H. Implications of three-dimensional numerical simulations of welding of large structures. Weld. J. 1992, 71, 55–62.Search in Google Scholar
13. Michaleris, P., Feng, Z., Campbell, G. Evaluation of 2D and 3D FEA models for pre-dicting residual stress and distortion. In Pressure Vessel and Piping Conference; ASME, 1997.Search in Google Scholar
14. Jpapazoglou, V., Masubuchi, K. Numerical analysis of thermal stresses during welding including phase transformation effects. J. Pressure Vessel Technol. 1982, 104, 198–203. https://doi.org/10.1115/1.3264204.Search in Google Scholar
15. Rybicki, E. F., Schmueser, D. W., Stonesifer, R. B., Groom, J. J., Mishler, H. W. A finite-element model for residual stresses and deflections in girth-butt welded pipes. J. Pressure Vessel Technol. 1978, 100, 256–262. https://doi.org/10.1115/1.3454464.Search in Google Scholar
16. Oddy, A. S., Goldak, J. A., Mcdill, J. M. J. Numerical analysis of transformation plasticity in 3 D finite element analysis of welds. Eur. J. Mech. A Solid. 1990, 9, 253–263.Search in Google Scholar
17. Tekriwal, P., Mazumder, J. Finite element analysis of three-dimensional tranient heat transfer in GMA welding. Weld. J., 1988, 67, 150–156.Search in Google Scholar
18. Tekriwal, P., Mazumder, J. Transient and residual thermal strain–stress analysis of GMAW. J. Eng. Mater. Technol. 1991, 113, 336–343. https://doi.org/10.1115/1.2903415.Search in Google Scholar
19. Tsai, C. L., Park, S. C., Cheng, W. T. Welding distortion of a thin-plate panel structure. Weld. J 1999, 78, 156–165.Search in Google Scholar
20. Jose, M. J., Kumar, S. S., Sharma, A. Vibration assisted welding processes and their influence on quality of welds. Sci. Technol. Weld. Join. 2016, 21, 243–258. https://doi.org/10.1179/1362171815Y.0000000088.Search in Google Scholar
21. Thavamani, R., Balusamy, V., Nampoothiri, J., Subramanian, R., Ravi, K. R. Mitigation of hot cracking in Inconel 718 super alloy by ultrasonic vibration during gas tungsten arcwelding. J. Alloys Compd. 2018, 740, 870–878. https://doi.org/10.1016/j.jallcom.2017.12.295.Search in Google Scholar
22. Anand, K., Elangovan, S. Optimizing the ultrasonic inserting parameters to achieve maximum pull – out strength using response surface methodology and generic algorithm integration technique. Measurement. 2017, 99, 263–2241. https://doi.org/10.1016/2Fj.measurement.2016.12.025.Search in Google Scholar
23. Anand, K., Elangovan, S. Modelling and multi-objective optimization of ultrasonic inserting parameters through fuzzy logic and generic algorithm. J. Braz. Soc. Mech. Sci. Eng. 2019, 41, 1678–5878. https://doi.org/10.1007/S40430-019-1685-Z.Search in Google Scholar
24. Parrini, L. New technology for the design of advanced ultrasonic transducers for high-power applications. Ultrasonics 2003, 41, 261–269. https://doi.org/10.1016/s0041-624x(02)00450-x.Search in Google Scholar PubMed
25. Rani, M. R., Prakasan, K., Rudramoorthy, R. Studies on thermo-elastic heating of horns used in ultrasonic plastic welding. Ultrasonics 2015, 55, 123–132. https://doi.org/10.1016/j.ultras.2014.07.005.Search in Google Scholar PubMed
26. Rani, M. R., Prakasan, K. Studies on high density polyethylene in the far-field region in ultrasonic welding of plastics. Polym.-Plast. Technol. Eng. 2008, 47, 762–770. https://doi.org/10.1080/03602550802188649.Search in Google Scholar
27. Zhang, C., Li, L. A coupled thermal-mechanical analysis of ultrasonic bonding mechanism. Metall. Mater. Trans. B 2009, 40, 196–207. https://doi.org/10.1007/s11663-008-9224-9.Search in Google Scholar
28. Zain, A., Habibollahharon, S., Sharif Optimization of process parameters in the abrasive waterjet machining using integrated SA – GA. Appl. Soft Comput. 2011, 11, 5350–5359. https://doi.org/10.1016/j.asoc.2011.05.024.Search in Google Scholar
29. Islam, M., Buijk, A., Rais-Rohani, M., Motoyama, K. Process parameter optimization of lab joint fillet weld based on FEM-RSM-GA integration technique. Adv. Eng. Software 2015, 79, 127–136. https://doi.org/10.1016/j.advengsoft.2014.09.007.Search in Google Scholar
© 2023 Walter de Gruyter GmbH, Berlin/Boston
Articles in the same Issue
- Frontmatter
- Editorial
- Additive manufacturing and allied technologies
- Original Papers
- Influence of process parameters on ageing and free vibration characteristics of fiber-reinforced polymer composites by fusion filament fabrication process
- 3D biomimetic scaffold’s dimensional accuracy: a crucial geometrical response for bone tissue engineering
- Investigation of mechanical and microstructure properties of metal inert gas based wire arc additive manufactured Inconel 600 superalloy
- Study on the influence of surface roughness on tensile and low-cycle fatigue behavior of electron beam melted Ti‐6Al‐4V
- Effect of tool pin profile on the heat generation model of the friction stir welding of aluminium alloy
- Effect of clamping position on the residual stress in wire arc additive manufacturing
- Effect of welding speed on butt joint quality of laser powder bed fusion AlSi10Mg parts welded using Nd:YAG laser
- Mechanical behaviour, microstructure and texture studies of wire arc additive manufactured 304L stainless steel
- Evolution of microstructure and properties of CoCrFeMnNi high entropy alloy fabricated by selective laser melting
- Effect of laser energy density on surface morphology, microstructure and mechanical behaviour of direct metal laser melted 17-4 PH stainless steel
- The influence of rheology in the fabrication of ceramic-based scaffold for bone tissue engineering
- Behaviour of glass fiber reinforced polymer (GFRP) structural profile columns under axial compression
- Desirability function analysis approach for optimization of fused deposition modelling process parameters
- Effect of robotic weaving motion on mechanical and microstructural characteristics of wire arc additively manufactured NiTi shape memory alloy
- Rapid tooling of composite aluminium filled epoxy mould for injection moulding of polypropylene parts with small protruded features
- Investigation of microstructural evolution in a hybrid additively manufactured steel bead
- Fused filament fabricated PEEK based polymer composites for orthopaedic implants: a review
- Design of fixture for ultrasonic assisted gas tungsten arc welding using an integrated approach
- Effect of post-processing treatment on 3D-printed polylactic acid parts: layer interfaces and mechanical properties
- Investigating the effect of input parameters on tool wear in incremental sheet metal forming
- Microstructural evolution and improved corrosion resistance of NiCrSiFeB coatings prepared by laser cladding
- Microstructure and electrochemical behaviour of laser clad stainless steel 410 substrate with stainless steel 420 particles
- News
- DGM – Deutsche Gesellschaft für Materialkunde
Articles in the same Issue
- Frontmatter
- Editorial
- Additive manufacturing and allied technologies
- Original Papers
- Influence of process parameters on ageing and free vibration characteristics of fiber-reinforced polymer composites by fusion filament fabrication process
- 3D biomimetic scaffold’s dimensional accuracy: a crucial geometrical response for bone tissue engineering
- Investigation of mechanical and microstructure properties of metal inert gas based wire arc additive manufactured Inconel 600 superalloy
- Study on the influence of surface roughness on tensile and low-cycle fatigue behavior of electron beam melted Ti‐6Al‐4V
- Effect of tool pin profile on the heat generation model of the friction stir welding of aluminium alloy
- Effect of clamping position on the residual stress in wire arc additive manufacturing
- Effect of welding speed on butt joint quality of laser powder bed fusion AlSi10Mg parts welded using Nd:YAG laser
- Mechanical behaviour, microstructure and texture studies of wire arc additive manufactured 304L stainless steel
- Evolution of microstructure and properties of CoCrFeMnNi high entropy alloy fabricated by selective laser melting
- Effect of laser energy density on surface morphology, microstructure and mechanical behaviour of direct metal laser melted 17-4 PH stainless steel
- The influence of rheology in the fabrication of ceramic-based scaffold for bone tissue engineering
- Behaviour of glass fiber reinforced polymer (GFRP) structural profile columns under axial compression
- Desirability function analysis approach for optimization of fused deposition modelling process parameters
- Effect of robotic weaving motion on mechanical and microstructural characteristics of wire arc additively manufactured NiTi shape memory alloy
- Rapid tooling of composite aluminium filled epoxy mould for injection moulding of polypropylene parts with small protruded features
- Investigation of microstructural evolution in a hybrid additively manufactured steel bead
- Fused filament fabricated PEEK based polymer composites for orthopaedic implants: a review
- Design of fixture for ultrasonic assisted gas tungsten arc welding using an integrated approach
- Effect of post-processing treatment on 3D-printed polylactic acid parts: layer interfaces and mechanical properties
- Investigating the effect of input parameters on tool wear in incremental sheet metal forming
- Microstructural evolution and improved corrosion resistance of NiCrSiFeB coatings prepared by laser cladding
- Microstructure and electrochemical behaviour of laser clad stainless steel 410 substrate with stainless steel 420 particles
- News
- DGM – Deutsche Gesellschaft für Materialkunde
