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Research Papers

Analytical Modeling of Metal Transfer for GMAW in the Globular Mode

[+] Author and Article Information
U. Ersoy, E. Kannatey-Asibu, S. J. Hu

Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125

J. Manuf. Sci. Eng 130(6), 061009 (Nov 04, 2008) (8 pages) doi:10.1115/1.3006317 History: Received April 04, 2007; Revised August 22, 2008; Published November 04, 2008

A lumped parameter dynamical model is developed to describe the metal transfer for gas metal arc welding in the globular mode. The oscillations of molten drop are modeled using a mass-spring-damper system with variable mass and spring coefficient. An analytical solution is developed for the variable coefficient system to better understand the effect of various model parameters on the drop oscillations. The effect of welding drop motion on the observed current and voltage signals is investigated, and the model agrees well with the experimental results. Furthermore, the effect of wire feeding rate (or welding current) on the metal transfer cycle time is studied, and the model successfully estimates the cycle times for different wire feeding rates. Possible regions of unstable metal transfer are investigated both by the model and experiments. The model can be used to identify the range of welding wire feed rates that results in stable metal transfer during the globular mode of metal transfer.

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Copyright © 2008 by American Society of Mechanical Engineers
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Figures

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Figure 1

Lumped parameter model for a weld drop

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Figure 2

Numerical solution versus approximate solution (k0=0.2,A0=17e−3,m0=5e−8,ṁ=1e−3,k̇=−0.05,b=5e−5)

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Figure 3

Identification of drop oscillations and detachment instants from measured current/voltage

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Figure 5

Features from the measured current: (a) amplitude, (b) drop oscillation period, and (c) metal transfer cycle time

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Figure 6

Simulation versus experiment for current and arc voltage

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Figure 7

Cycle times and number of drop oscillations at various wire feeding rates

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Figure 8

Percentage of number of oscillations at given wire feeding rates

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Figure 9

Cycle time variation with increasing wire feeding rate

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Figure 10

Comparison of the mean cycle time by experiment and the simulation

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Figure 11

Period doubling observed at 240 ipm

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