"Applications of Finite Element Method in Academic and Industrial Research"

Evolution of modeling and simulation in welding

Dr.-Ing.G.Buvanashekaran
Welding Research Institute
Bharat Heavy Electricals Ltd., Tiruchirappalli 620 01 Email: gbs@bheltry.co.in

Modeling ....Simulation
Simulation is the imitation of the operation of a real-world process or system over time. The act of simulating something first requires that a model be developed;

Wooden, mechanical, horse simulator during World War I.

This model represents the key characteristics or behaviors/functions of the selected physical or abstract system or process. The model represents the system itself, whereas the simulation represents the operation of the system over time.

Modeling
A model is a logical description of how a system performs. Simulations involve designing a model of a system and carrying out experiments on it as it progresses through time. Eg. the board game Monopoly is a model of a real system the hotels and facilities of Atlantic City. When you play Monopoly, you are simulating that system. Simulation with ExtendSim means that instead of interacting with a real system, you create a model which corresponds to it in certain aspects.

Modeling
You can use a model to describe how a realworld activity will perform. Models also enable you to test hypotheses at a fraction of the cost of actually undertaking the activities which the models simulate. For example, if you are a hardware designer, you can use ExtendSim to simulate the performance of a proposed system before building it.

Modeling
One of the principal benefits of a model is that you can begin with a simple approximation of a process and gradually refine the model as your understanding of the process improves. This step-wise refinement enables you to achieve good approximations of very complex problems surprisingly quickly. As you add refinements, your model becomes more and more accurate.

Modeling
A computer model, as used in modeling and simulation science, is a mathematical representation of somethinga person, a building, a vehicle, a treeany object. A model also can be a representation of a processa weather pattern, traffic flow, air flowing over a wing. Models are created from a mass of data, equations and computations that mimic the actions of things represented. Models usually include a graphical display that translates all this number crunching into an animation that you can see on a computer screen or by means of some other visual device. Models can be simple images of thingsthe outer shell, so to speakor they can be complex, carrying all the characteristics of the object or process they represent. A complex model will simulate the actions and reactions of the real thing.

Why to do Modeling

Modeling is phenomenon.

the

art

of

abstracting

or

representing

Geometric modeling and simulation via computers have reached a level to replace the real-life prototypes or trial runs. A geometric model is defined as the complete representation of an object that includes both its graphical and non-graphical information.

Advantage Actual Experiments Vs Modeling

Compared with experimental methods, the computer

simulation based on various numerical methods is becoming more and more popular in the investigations of the welding process because of its reduced cost, increased speed of computation and the capability for analyzing the effects of different factors involved in the process separately.

Why simulation technique

In the computer aided product design, simulation techniques offer the possibility to examine the production process as well as the resulting properties of the product at an early stage of product development. The process of product design has two main phases. First, a virtual phase where the product, manufacturing processes and manufacturing systems are designed by means of computers and software. Second, the physical phase, where the actual realization of the product is achieved.

Why simulation technique (Contd.)

Computer based simulations offer the possibility to examine different aspects of the process without building a physical prototype of the product.

Simulation
Simulation provides a method for checking your understanding of the world around you and helps you produce better results faster. A simulation program like ExtendSim is an important tool that you can use to: Predict the course and results of certain actions. Understand why observed events occur. Identify problem areas before implementation. Explore the effects of modifications. Confirm that all variables are known. Evaluate ideas and identify inefficiencies. Gain insight and stimulate creative thinking. Communicate the integrity and feasibility of your plans.

Simulation
Simulations (and models, too) are abstractions of reality. Often they deliberately emphasize one part of reality at the expense of other parts. Sometimes this is necessary due to computer power limitations. Sometimes it's done to focus your attention on an important aspect of the simulation. Whereas models are mathematical, logical, or some other structured representation of reality, simulations are the specific application of models to arrive at some outcome

Simulation
Three types of simulations Simulations generally come in three styles: live, virtual and constructive. A simulation also may be a combination of two or more styles. Within these styles, simulations can be sciencebased (where, for example, interactions of things are observed or measured), or involve interactions with humans

Live simulations
Typically involve humans and/or equipment and activity in a setting where they would operate for real. Think war games with soldiers out in the field or manning command posts. Time is continuous, as in the real world. Another example of live simulation is testing a car battery using an electrical tester.

Virtual simulations
Typically involve humans and/or equipment in a computer-controlled setting. Time is in discrete steps, allowing users to concentrate on the important stuff, so to speak. A flight simulator falls into this category. A welder training simulator also the same category

Constructive simulations
Typically do not involve humans or equipment as participants. Rather than by time, they are driven more by the proper sequencing of events. The anticipated path of a hurricane might be "constructed" through application of temperatures, pressures, wind currents and other weather factors. Science-based simulations are typically constructive in nature.

Requirements of a weld
Fusion zone: a mixture of filler metal and base metal melted together homogeneously due to convection as in casting. Epitaxial grain growth (casting)
Butt joint
Weld Interface Reinforcement

HAZ

Fusion zone BM

Weld interface a narrow boundary immediately solidified after melting. Heat Affected Zone (HAZ) below melting but substantial microstructural change in the base material (heat treating) Unaffected base metal zone (UBMZ) high residual stress

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Dr G Buvanashekaran, WRI

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Mathematical Modeling
Inputs Processing Output OR Result

In welding: Input Processing Current Voltage Welding speed

Butt joint
Weld Interface Reinforcement HAZ

Results Reinforcement Penetration

Fusion zone BM

Mathematical Modeling

Input X1, X2..

Simple mathemaical operations

Output Y=m1x1+c .

Direct effect Effect of independent variable only Simple empirical equation or polynomial eqn

Schaeffler diagram
35 30 Austenite 25

10%F

20
A+M 15 10 Martensite 5 M+F Ferrite 20 25 30 35 Aust.+Ferrite

10

15

Cr equivalent=C+1.5Si+Mo+0.5Nb

Mathematical Modeling
Simple mathemaical operations
Higher order of polynomial eqn

Input X1, X2..xn

Output Y=m1x1+m 2x2..+mn +1*m1m2 .

Interactive effects 0f all the variables

Grain coarsening

Martensite

Reduce

Ductility

Toughness

Reduce

Weldability

Mathematical model development

WHY FEM ?
The Heat developed during welding process intermittently interacts with the work piece over very short time intervals, resulting in very rapid heating and cooling cycles. The weld bead is the product of a number of overlapping spot welds, and every point in the weld area experiences a complex series of thermal cycles during the passage of the welding heat source. This complexity implies that analytical (mathematical) modeling techniques are almost impossible. The Finite Element Modeling, therefore, is the preferred option, although the analysis requires a very large number of small time steps.

Laser Beam Welding

The laser welding is a keyhole welding process having concentrated heat input. To obtain the required weld profile and quality of weld, correct process parameters have to be selected.
Laser beam Plasma Keyhole

Input Parameters Beam power Welding speed Beam Angle Spot Diameter

Melt pool Base material

Output Parameters Bead width Depth of penetration

Schematic representation of key hole welding

Modes of Welding
Weld Bead Geometries
Conduction Mode Cond+Penet. Mode Penetration Mode

P=102 w/cm2
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P=103 w/cm2
Dr G Buvanashekaran, WRI

P=104 w/cm2
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Mode 1: Conduction welding

Heat is not concentrated Heat supplied in a wider area

Experimental
BP 600W, WS 800mm/min, BA 5o

Finite Element Simulation

Mode 2: Conduction + Penetration

Heat concentration and speed of source movement better

Experimental
BP 1000W, WS 800mm/min, BA 5o

Finite Element Simulation

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Mode:3 Penetration / key-hole welding

Highly concentrated heat input High processing speeds Experimental
Finite Element Simulation

BP 1400W, WS 800mm/min, BA 5o
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Weld Geometry

(a)

(b)

(c)

Weld geometry from Finite Element Simulation at three different welding speed (a) 800 (b) 1400 and (c) 2000 mm/min with constant beam power 1400W, spot diameter 0.8 mm and Beam angle 5o

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Temperature Plots
Beam power - 1250 W, welding speed - 750 mm/min beam angle 90o (straight beam)

Vertical interfacial distribution of the temperature field.

Comparison of fusion zone: (a) microstructure image, (b) FEM analysis

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Temperature Vs. Distance

Laser Beam Laser Beam

(a)

The distribution of temperature in (a) depth direction and (b) radial direction
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DOP

Temperature Vs. Time

Laser Beam Laser Beam

Thermal cycles of the workpiece (a) on the top surface and (b) in depth direction.
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Weld Geometry
Constant Beam Power

Increasing Beam Angle

Increasing Welding Speed

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Weld Geometry
Constant Welding Speed

Increasing Beam Angle

Increasing Beam Power

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Comparison Exp. Vs. FEM

(a)

(b)

Weld pool shape between (a) Experimental investigation and (b) finite element simulation

Bead Shape
Beam power - 1250 W, welding speed - 500 mm/min

30o

45o 60o

BA - 30o

BA - 45o
BA - 60o

APPLICATION OF ARTIFICIAL NEURAL NETWORK

ARTIFICIAL NEURAL NETWORKS..

Neural Networks (NN) - composed of simple elements operating in parallel Elements are inspired by biological nervous systems Network function determined by the connections between elements. NN training perform a function by adjusting the values of the connections (weights) between elements.

ARTIFICIAL NEURAL NETWORKS

The FFNN is adopted for modeling Artificial Neuron evaluates the input and determines the strength of each through its weighing factor. A FFNN consists of layer of processing units, each layer feeding i/p to the next layer in a feed forward manner through a set of connection strength (or) weights.

BACK PROPAGATION ALGORITHM

Propagation of error backwards from the Output Layer to Hidden Layer in order to update the weights leading to the units in a HL The error in the output is propagated backwards only to determine the weight updates The simplest implementation of BP learning updates the network weights and biases in the direction in which the performance function decreases most rapidly. Network adjusted, based on comparison of the output and the target, until the network output matches the target.

NEURAL NETWORKS BACK PROPAGATION

ANN
Target

Input

NEURAL NETWORK Including connections ( called weights) between neurons Adjust Weights

Compare Output

Initialization

Present the data Feed Forward Get Output and Error

Back Propagation

FLOW CHART OF FEED FORWARD NEURAL NETWORK WITH

Initialize weights and learning Parameters

YES Any other data NO

BACKPROPAGATION

Get Out put of hidden layer & Output layer

Is Error Acceptable Up date weights.

Iterate next Epoch.

LASER WELDING HEAD

EXPERIMENTAL DESIGN
Full Factorial design 81 Trials
BEAM POWER 500, 1000 & 1500 Watts

WELDING SPEED 400, 800 & 1200 mm/min

FOCAL LENGTH 80, 120 & 160 mm

GAS FLOW RATE 5, 10 & 15 lt/min

INPUT AND OUTPUT DATA

Trial WS, FL, Gas, DOP, BW, Sl.no BP,Watts Seq mm/min mm lpm mm mm 1 28 500 400 160 15 0.431 1.127 2 47 500 400 160 10 0.314 0.684 3 39 500 400 160 5 0.460 1.216 4 1 500 400 120 15 0.363 1.135 5 20 500 400 120 10 0.587 1.094 6 12 500 400 120 5 0.575 1.097 7 55 500 400 80 15 0.862 2.283 8 74 500 400 80 10 0.544 1.299 9 66 500 400 80 5 0.727 1.820 10 34 500 800 160 15 0.287 0.885

APPROACH TO ANALYSIS OF DATA

Raw data of Input (set parameter) and

Output parameters (measured data) are

scaled a sub-interval of [0.1].

Practical region of the data is chosen to in

the interval of 0.1 to 0.9. All the raw data (P) are normalized (Pn)

Pn = [(0.9-0.1)/(Pmax-Pmin) * (P-Pmin)]+0.1

APPROACH TO ANALYSIS OF DATA

Normalized data analysed using back propagation learning algorithm Learning rate (as 0.01) and Goal setting (as 0.0001) selected for training the network. Simulated models de-normalized (Y) to enable comparison with the measured data:

Y = Min[a] + (Pn lower value)*(Max[a]-Min[a])/(upper value-lower value)

SAMPLE DATA - NORMALISED

Seq.

Sl. No 1 2 3 4 5

Raw Data BP WS 400 400 400 400 400 FL 160 160 160 120 120 GF 15 10 5 15 10 DOP BW .431 .314 .46 .363 .587 1.127 .684 1.216 1.135 1.094 BP WS

Normalised data FL GF DOP BW .9 .5 .1 .9 .5 .1638 .3164 .1269 .1727 .1730 .3453 .1424 .3190 .2132 .3057

28 47 39 1 20

420 510 500 460 500

.1000 .1000 .9 .1610 .1000 .9 .1542 .1000 .9 .1271 .1000 .5 .1542 .1000 .5

ANN ARCHITECTURE FOR ANALYSIS

INPUT LAYER HIDDEN LAYER OUTPUT LAYER

BEAM POWER DEPTH OF PENETRATION

WELDING SPEED BEAD WIDTH

FOCAL LENGTH

GAS FLOW RATE

Combination of NN models analysed

1. 4X4X2
2. 4X6X2 3. 4X8X2 4. 4X8X8X2 : 4 IN, 1 HL with 4 neuron and 2 ON : 4 IN, 1 HL with 6 neuron and 2 ON : 4 IN, 1 HL with 8 neuron and 2 ON : 4 IN, 2 HL with 8 neuron each and 2 ON

5. 4X16X16X2: 4 IN, 2 HL with 16 neuron each and 2 ON 6. 4X6X6X2 : 4 IN, 2 HL layer with 6 neuron each and 2 ON

7. 4X4X4X2

: 4 IN, 2 HL layer with 4 neuron each and 2 ON

(Input neurons X Hidden layer & neurons X Output neurons)

80 70 60 50 40 30 20 10 0
Percentage STDEV

DOP BEAD WIDTH

4X 4X 2 4X 6X 2

4X 8X 2 4x 8x 8x 2 4x 16 x1 6x 2 4x 6x 6x 2 4x 4x 4x 2
Network model

CHOSEN NEURAL NETWORK MODEL CONFIGURATION: 4X6X2 (4 input neurons, 1 Hidden layer with 6 neurons and two output neurons)

SCREEN FOR BACK PROPAGATION TRAINING OF DATA WITH EPOCHS AND GOAL SETTING

GOAL SETTING AND PERFORMANCE ACHIEVED WITH THE 4X6X2 NN MODEL

ARTIFICIAL INTELLIGENCE BASED EXPERT SYSTEM

EXPERT SYSTEM FOR PREDICTION OF LASER OUTPUT PARAMETERS BASED ON THE CHOSEN NN MODEL

Simulator
A simulator is a device that may use any combination of sound, sight, motion and smell to make you feel that you are experiencing an actual situation. Some video games are good examples of lowend simulators. For example, you have probably seen or played race car arcade games

Simulator
The booths containing these games have a steering wheel, stick shift, gas and brake pedals and a display monitor. You use these devices to "drive" your "race car" along the track and through changing scenery displayed on the monitor. As you drive, you hear the engine rumble, the brakes squeal and the metal crunch if you crash. Some booths use movement to create sensations of acceleration, deceleration and turning. The sights, sounds and feel of the game booth combine to create, or simulate, the experience of driving a car in a race.

Simulation
Most people first think of "flight simulators" or "driving simulators" when they hear the term "simulation." But simulation is much more. Because they can recreate experiences, simulations hold great potential for training people for almost any situation Education researchers have, in fact, determined that people, especially adults, learn better by experience than through reading or lectures. Simulated experiences can be just as valuable a training tool as the real thing.

OVERVIEW
WeldTrainer is a welding simulator aimed for the vocational training world. Using cutting edge technology and real time motion tracking systems, Weldtrainer allows the user to be immersed into a welding room where virtual welding can be performed in real time in the same way that in real life.

OVERVIEW
The user can look, move and interact with environment into the virtual welding room as he pleases. Shield metal arc welding and MIG/MAG welding are simulated in Weldtrainer.

HARDWARE FEATURES
Weldtrainer has the following components: Computer where the simulation is performed and the 3D display is generated. Motion tracking system including different sensors for head and hand tracking. Virtual reality glasses for 3D visualization (one of the sensors is attached to this glasses). Real welding torch with 4 buttons and a trigger for software interaction (other sensor is placed inside the torch). Additional screen where the same image that the one seen in the glasses is displayed, therefore anyone around the simulator can watch what the user is doing.

HARDWARE FEATURES
All the interaction with the simulator is performed with the buttons placed in the welding torch and with the data tracked by the sensors. There is no need to remove the 3D glasses at any time to interact with all the simulator features including menus navigation.

SOFTWARE FEATURES
The user is immersed into a 3D representation of a real welding room displayed on the 3D glasses, where the users head marks the point of view in real time and the right hand controls the welding torch. Weldtrainer simulation is powered by a mathematical model powerful enough to simulate in real time all the consequences of every user action. Weld beads layout and aspect is 100% driven by the user actions and environment configuration, without any kind of prebuilt or scripted behavior.

SOFTWARE FEATURES
WeldTrainer simulates SMAW and MIGMAG welding. SMAW welding includes the simulation of electrodes of 2.5 mm, 3.25 mm and 4 mm. For all the welding styles, the simulator offers several modules with different exercises inside to perform and practice a good number of situations.

SOFTWARE FEATURES
Actually 30 different exercises exists for each welding style, packed in 3 modules:
Deposition of weld beads on plates in PA position. Fillet welds. Butt welds of plates.

SOFTWARE FEATURES
Every exercise has its own theory screen with all the relevant information related to the exercise displayed. Within every theory screen, text and images explain to user every detail of the exercise to be performed. The simulator performs real time errors checking during the simulation. Distance, orientation angles and speed are checked and displayed to the user. On top of that, every exercise gets recorded, allowing a 3D interactive review of every exercise performed.

SOFTWARE FEATURES
At the end of each welding pass the simulator creates a telemetric report of it, displaying percentages of correctness for each parameter under control in the exercise. These reports can also be seen directly from the menu, therefore allowing for a global evaluation of the exercise performance.

SOFTWARE FEATURES
User can freely change the welding parameters at any time in the simulation using the buttons present on the welding torch. This way, intensity can be modified in real time for SMAW, and intensity and wire speed as well for MIGMAG.

SOFTWARE FEATURES
The real time 3D graphics displayed on the simulation are powered by the company exclusive rendering technology. Using a very advanced lighting system, complex materials, particles systems, image post processing effects (along many other advance features), Weldtrainer technology and visual quality outperform every other welding simulator available in the market so far.

SOFTWARE FEATURES
NOTE: Every picture shown in this presentation is directly taken from the simulator output display without tweaks or modifications.

SIMULATOR KEY POINTS

The student performs a higher number of actual welding hours because all of the hours taught using the simulator involve actual welding (no need to change parts, wait for them to cool, remove slag, etc). The training process cost is reduced. The simulator shortens the training time and heavily reduces the consumption of materials. Every possible accident or dangerous situation is completely avoided with the use of the simulator. The initial learning curve for students is faster. Students can understand and master faster and better the key aspects of welding (such as distance, angles and welding speed control). 2 different types of welding in the same device.

Improvements to the training

Thank You