Automated and Low Computational Cost Thermo-Mechanical Simulation of Arbitrary GMAW T-Joint Welds Using a Moving Heat Source
Sebastian Santarrosa-Rodriguez, Israel Martínez-Ramírez, Motomichi Yamamoto, Rocio A. Lizarraga-Morales, Felipe J. Torres, Isaí Espinoza-Torres, Víctor Manuel Vega-Gutierrez
TL;DR
This paper introduces an automated, low-cost simulation method for predicting thermal and mechanical effects in GMAW T-joint welds using finite element analysis.
Contribution
The novelty is an automated APDL-based thermo-mechanical simulation method with a volume element strategy for reduced computational cost.
Findings
The method reduces computational time by up to 50% while maintaining accuracy.
Validation with experimental results shows good agreement in temperature and displacement.
The approach enables efficient parametric analysis of T-joint geometries and welding conditions.
Abstract
Gas Metal Arc Welding (GMAW) is widely adopted in automated manufacturing industries where the accurate prediction of thermal fields and welding-induced distortions is essential to ensure joint integrity of the parts; however, finite element modeling, as the most reliable non-destructive predictive approach, remains time-consuming and highly user-specialized. This work presents an automated and low computational cost thermo-mechanical finite element methodology implemented in Ansys Parametric Design Language (APDL) for the parametric analysis of GMAW T-joints, integrating automated geometry generation, meshing, heat source implementation, and thermo-mechanical modeling for different beam and weld seam dimensions under continuous or intermittent single-pass configurations. A volume element selection strategy is introduced to limit heat input calculations to the active weld pool region,…
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Taxonomy
TopicsWelding Techniques and Residual Stresses · Laser and Thermal Forming Techniques · Topology Optimization in Engineering