Implementation of weave patterns by path parameterization in the simulation of welding processes by the finite element method

Abstract

One of the most common practices to produce high-quality welds with greater efficiency is the execution of arc weaving. Although the finite element method (FEM) has been widely used in the simulation of welding, the mathematical models of heat sources representing the electric arc do not cover the execution of weave patterns, and adaptations are, therefore, required. In the present paper, the incorporation of these patterns on FEM simulations of welding is based on the parameterization of the path traveled by the heat source. Two case studies using ANSYS Mechanical APDLⓇ were performed, in which the proposed approach was compared with the coordinate transformation method, the most commonly used technique for the implementation of weaving, based on data from Hu et al. (Sci Tech Weld Joi 11:358–365 2006) and also from an experimental analysis. The results revealed that the path parameterization method is as capable to represent arc weaving in welding simulations as the coordinate transformation method. Moreover, the path parameterization method has the advantage of being able to model many different weave patterns, in an easier-to-implement way. Also, the simulation may provide relevant information regarding the thermal cycle of weaving welding process, which can be used for the adjustment of welding parameters and the prediction of welding defects.