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Research Papers

Simulation of Dynamic Behavior and Prediction of Optimal Welding Current for Short-Circuiting Transfer Mode in GMAW

[+] Author and Article Information
Ying Wang

Tianjin Key Laboratory of Advanced
Joining Technology,
School of Materials Science and Engineering,
Tianjin University,
Nankai District,
Tianjin 300072, China
e-mail: wying2012@tju.edu.cn

Lijun Wang

Professor
Tianjin Key Laboratory of Advanced
Joining Technology,
School of Materials Science and Engineering,
Tianjin University,
Nankai District,
Tianjin 300072, China
e-mail: wanglijun@tju.edu.cn

Xiaoqing Lv

Tianjin Key Laboratory of Advanced
Joining Technology,
School of Materials Science and Engineering,
Tianjin University,
Nankai District,
Tianjin 300072, China
e-mail: xiaoqinglv@tju.edu.cn

1Corresponding author.

Manuscript received August 31, 2014; final manuscript received December 10, 2015; published online February 19, 2016. Assoc. Editor: Wayne Cai.

J. Manuf. Sci. Eng 138(6), 061011 (Feb 19, 2016) (10 pages) Paper No: MANU-14-1453; doi: 10.1115/1.4032259 History: Received August 31, 2014; Revised December 10, 2015

An improved “mass–spring” model to analyze the entire short-circuiting transfer (SCT) dynamic process based on the association between the arcing and circuiting phases has been proposed. This paper analyses the basic characteristics of displacement of the droplet mass center and oscillation velocity of droplet variation. In addition, the effect of welding current on the short-circuiting frequency is studied. The results of the simulations conducted agree well with the experimental results obtained. An analysis method for optimal welding current during SCT is also proposed, and the droplet transport stability is discussed. Simulation results demonstrate that the relative displacement of the droplet mass center and the average equivalent diameter of the transfer droplets are at a minimum under the optimal welding current condition. This research provides a reference for further simulation of the SCT process and useful guidance for the selection of optimum technics parameters.

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References

Figures

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Fig. 1

Schematic diagram of the electrodes in GMAW

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Fig. 2

Calculation of initial displacement of droplet

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Fig. 3

Variations of displacement and velocity occurred in droplet oscillation

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Fig. 4

Comparison of the predicted and experimental results

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Fig. 5

Displacement variation in droplet oscillation I = 65 A, Ib = 43 A, and Is = 333 A

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Fig. 6

Displacement variation in droplet oscillation I = 100 A, Ib = 84.5 A, and Is = 193 A

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Fig. 7

Displacement variation in droplet oscillation I = 111 A, Ib = 94 A, and Is = 200 A

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Fig. 8

Displacement variation in droplet oscillation I = 140 A, Ib = 108 A, and Is = 240 A

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Fig. 9

Distribution diagram of droplet equivalent diameter

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Fig. 10

Relative displacement variation of droplets

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Fig. 11

Average droplet equivalent diameter variation

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Fig. 12

Comparison of the predicted and experimental results with different values of α

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