The Nonlinear Time-Varying Response of Dynamic Thermal Tensioning for Welding-Induced Distortion Control

[+] Author and Article Information
Jun Xu, Wei Li

Department of Mechanical Engineering, University of Washington, Seattle, WA 98195-2600

J. Manuf. Sci. Eng 129(2), 333-341 (Oct 06, 2006) (9 pages) doi:10.1115/1.2540708 History: Received December 30, 2005; Revised October 06, 2006

This paper presents a dynamic thermal tensioning method to control the welding induced distortion under production variation. The new method determines the optimal thermal tensioning parameters based on real-time distortion measurements. The paper is focused on a systematic study on the structural response and the development of an automatic control algorithm for the dynamic thermal tensioning process. A thermomechanical finite element model was used to study preheating effects in a gas metal arc welding process. A model predictive strategy was adopted for automatic distortion control. It has been found that the response of the dynamic thermal tensioning process is nonlinear and time varying. However, the response model can be linearized based on the superposition principle. A threshold-based control algorithm is developed and demonstrated using both simulation and experimental results.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

An overview of the experimental setup

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Figure 2

Three major types of welding induced distortion: (a) bow, (b) banana, and (c) twist

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Figure 3

A schematic of the preheating strategy for decoupled distortion control

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Figure 4

The meshed finite element model of the box beam structure

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Figure 5

Material properties used in the finite element model

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Figure 6

Simulation results showing the twist response during the preheating process: (a) twist response at the fifth step and (b) twist response at the 17th step

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Figure 7

Characteristic twist response

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Figure 8

Twist responses at different temperatures

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Figure 9

Twist responses with different step inputs (preheating temperature 250°C)

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Figure 10

Verification of the superposition principle (preheating temperature 250°C): (a) preheating input and (b) corresponding twist response

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Figure 11

Superposed preheating input

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Figure 12

Interpolation of the response curves

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Figure 13

The flow chart of the threshold-based control algorithm

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Figure 14

Effect of threshold value

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Figure 15

Effect of time interval (a) twist response and (b) preheating actions

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Figure 16

Experimental setup

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Figure 17

Examples of twist control results: (a) ε=0.75mm, Δ=5s, (b) ε=1.5mm, Δ=5s, and (c) ε=1.0mm, Δ=5s

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Figure 18

The effectiveness of dynamic thermal tensioning method



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