Application of a Front Tracking Method in Gas Metal Arc Welding (GMAW) Simulation

[+] Author and Article Information
Guo Xu, Elijah Kannatey-Asibu

Department of Mechanical Engineering,  University of Michigan, Ann Arbor, MI 48109

William W. Schultz1

Department of Mechanical Engineering,  University of Michigan, Ann Arbor, MI 48109Schultz@umich.edu


Author to whom correspondence should be addressed.

J. Manuf. Sci. Eng 127(3), 590-597 (Sep 15, 2004) (8 pages) doi:10.1115/1.1949622 History: Received November 07, 2003; Revised September 15, 2004

A numerical model is developed to simulate the short-circuiting metal transfer process during gas metal arc welding (GMAW). The energy equation and the Marangoni convection are considered for the first time in analyzing the short-circuiting time. A front-tracking free surface method explicity tracks the profile of the liquid bridge. The electromagnetic field, distribution of velocity, pressure, and temperature are calculated using the developed model. Effects of welding current, surface tension temperature coefficient, and initial drop volume on short-circuiting duration time are examined. The results show that both the electromagnetic force and Marangoni shear stress play significant roles in short-circuiting transfer welding.

Copyright © 2005 by American Society of Mechanical Engineers
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Figure 2

Benchmarking problem set-up

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Figure 3

Effect of density ratio on isothermal drop oscillation

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Figure 4

Effect of viscosity ratio on isothermal drop oscillation

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Figure 12

Velocity distribution for two currents

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Figure 11

Neck diameter and maximum current density

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Figure 10

Bridge profiles for various welding currents

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Figure 9

Initial geometry

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Figure 8

Boundary conditions

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Figure 7

Comparison between the front tracking and VOF methods

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Figure 6

Oscillation period versus density and viscosity ratios

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Figure 1

Schematic representation of front tracking method

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Figure 5

Effect of time step on isothermal drop oscillation

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Figure 14

Marangoni effect (I=150A)

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Figure 13

Temperature distribution



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