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
Your Session has timed out. Please sign back in to continue.



Grahic Jump Location
Figure 1

An overview of the experimental setup

Grahic Jump Location
Figure 2

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

Grahic Jump Location
Figure 3

A schematic of the preheating strategy for decoupled distortion control

Grahic Jump Location
Figure 4

The meshed finite element model of the box beam structure

Grahic Jump Location
Figure 5

Material properties used in the finite element model

Grahic Jump Location
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

Grahic Jump Location
Figure 7

Characteristic twist response

Grahic Jump Location
Figure 8

Twist responses at different temperatures

Grahic Jump Location
Figure 9

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

Grahic Jump Location
Figure 10

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

Grahic Jump Location
Figure 11

Superposed preheating input

Grahic Jump Location
Figure 12

Interpolation of the response curves

Grahic Jump Location
Figure 13

The flow chart of the threshold-based control algorithm

Grahic Jump Location
Figure 14

Effect of threshold value

Grahic Jump Location
Figure 15

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

Grahic Jump Location
Figure 16

Experimental setup

Grahic Jump Location
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

Grahic Jump Location
Figure 18

The effectiveness of dynamic thermal tensioning method




Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In