Welding Sequence Optimization Of Plasma Arc
For Welded Thin Structures
Author(s)
M. B. Mohammed, W. Sun & T. H. Hyde
Abstract
Dividing the weld path into multiple seams that are welded sequentially in a
specific order is one of the most important and cost effective distortion and
residual stresses mitigation strategies. This is particularly important for welding
fabrication of thin structures. The number of sequence options resulting from
reordering seams increases explosively with the increase of the number of weld
seams. Investigating all sequences using experimental, analytical or
computational approaches requires substantial expenses in terms of time,
resources and cost and in many situations is practically impossible. Therefore,
welding industries tend to opt for small improvement and abandon the search for
the absolute optimum welding sequence, e.g. the welding sequence that produces
the absolute minimum welding induced distortion. This paper presents an
optimization procedure to improving the effectiveness of the search for an
optimized welding sequence. The optimization procedure is based on the
principles of genetic algorithms (GA), in which the finite element (FE) analysis
is used to produce the distortion information and direct the evolution of the GA
within the optimization. The capability of the optimization procedure to identify
an optimum welding sequence was demonstrated for the keyhole plasma arc
welding (KPAW) of two Ti-6Al-4V thin structures, being a flat plate and a
simplified replica of a portion of an aero-engine casing. The optimization
procedure developed in this study was capable of minimizing the welding
induced distortion by up to 55% and of improving the effectiveness of the search
for an optimized welding sequence by up to 98%.
Keywords: welding sequence, optimization, genetic algorithms, plasma arc
welding, finite element modelling.
Keywords
welding sequence, optimization, genetic algorithms, plasma arcwelding, finite element modelling.
Related Book
Other papers in this volume
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