Simulation For Control Of Sequential And Scanned Thermal Processing

Abstract

A thermal simulation of manufacturing processes with sequential and scanned torch motion is developed in this article and applied to the newly invented scan welding technique. The composite model consists of a numerical description of the solid conduction field, an analytical formulation of the melt circulation, and experimental calibration of the torch parameters. This simulation is used for a comparative analysis of serial and scanned thermal processing, with the latter resulting in a more uniform temperature distribution and smooth thermal gradients. In particular, scan welding deposits the entire weld bead length simultaneously at controlled solidification rates and material structure in the heat affected zone. The model serves as the foundation of thermal control systems of the torch power and motion, using real-time feedback of surface temperatures measured by infrared thermometry. The simulation is applicable to a large variety of thermal manufacturing techniques, such as arc cutting and laser machining.