Abstract
Welding is an important joining method in industrial manufacturing, and optimization techniques combined with advanced simulation methods in welding have greatly promoted the development of industries. Modeling the heat transfer phenomenon during the welding process can provide a basis for reliably calculating the temperature and residual stress fields of the weldments. Therefore, accurately describing the geometric parameters of the welding heat source model is crucial. An interactive computational procedure is proposed to achieve efficient automatic parameter calibration, which is combined numerical simulation with optimization algorithm. This procedure defines a novel objective function called the total fusion zone error, which measures the disparity in fusion zone shape. It calculates the fusion zone difference for each element near the weld line between the simulated value and the test value, and sums them up. The particle swarm algorithm (PSO) is then selected for the optimization procedure, with some improvement of continuously compressing the particle's search domain and replacing its un-computed fitness value by the neighboring particle's results to reduce the iterative computation time. Synthetically, the proposed procedure is implemented in ABAQUS software to automatically calculate the objective function during optimization iterations. In a case study, the two-curvature conical heat source model is deduced, its calibrated parameters conclude temperature field results with valuable accuracy and efficiency, through this proposed multi-software cooperation automated optimization process. The method proposed in this paper can achieve the requirement of accurate programmatic solution of heat source model parameters, reducing the dependence of simulation efficiency and accuracy on researchers' experience.
Published Version
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