Finite element simulation and optimization of orbital welding process parameters

Abstract

Orbital pipe welding is a welding method where the welding head rotates around a fixed vertical or horizontal pipe in orbital welding with an arc is rotated mechanically through 360° around a static work piece such as a pipe in a continuous process. Welding parameters play a vital role in joining of work piece using welding. In this research effort, combination of experimental and numerical approach is used in order to simulate and estimate optimum process conditions for orbital pipe welding process. The motive of this research effort is to simulate Orbital Pipe welding process and to evaluate the effect of various welding process parameters such as current, voltage, orbital velocity on performance parameters like temperature distribution, residual stresses and Tensile strength of welded pipes. To estimate optimum process parameter by experimental method is quite complicated, therefore simulation technique is used to predict the behaviour of selected process and performance parameters. In this paper, Orbital welding process is simulated using Finite Element Approach with the help of ANSYS mechanical APDL 14.5 analysis software. A three-dimensional finite element model assuming a Gaussian distribution heat source has been used to investigate the temperature distribution and residual stress distribution. Selected welding process parameter i.e. values of temperature of both simulated and experimental approaches are compared to validate the simulated model. The effect of input parameters like welding current, voltage, welding speed, gas flow rate on performance parameter temperature has been investigated and found that the peak temperature sharply increases with the above input parameters. The result of this research effort indicates that the developed models are capable of predicting the responses with negligible errors.