Welding Simulation Analysis

Welding Analysis by Simulation
Software
Name of Faculty Guide:
Prof. Pratik T. Kikani
Atmiya Institute of
Technology & Science
7th Fx PMMS
Zala Vijaysinh C. 170030119074
Solanki Hardik V. 170030119062
Solanki Mahavir D. 170030119063
Pariya Nayan A. 170030119501
Prepared By:

Abstract
Welding is a joining process used to join two similar or dissimilar metal
components by the application of with and without heat and pressure.
Currently industries are using different solid state welding process for
quality weld joints. Welding is time consuming and money consuming
process. Industries are needed defect free quality product. for analysis
purpose people are using experimental method to get optimum process
parameters for specific material weld. Currently industries are focusing on
sustainable manufacturing process. Sustainability covers three aspects
which are economical, environment & social. For economical point of
view one should go for simulation of manufacturing process. Simulation of
welding provides facilities of performing different virtual experimentation
for evaluating different weld variables and avoid expensive trials of actual
welding experiments and provides material behavior during welding
process. so the project work is focusing on simulation of welding process.
Key Words:
Welding Simulation
Sustainability
Welding

Introduction
Welding is a joining process used to join two
similar or dissimilar metal components by the
application of heat and without heat. The
strengths of these joints are of great concern as
in today’s world these joints find a very crucial
place in growths of structures and machine parts
and it is the strength of such joints and welding
which decides the service life of such structures
and thus prevent from loss whether be it human
loss, economic loss or the any such losses.

Objectives
To verify the quality of welding seams. i.e. By
brittle metallurgical phases, hardness and
Effects of preheating.
Examine the material behavior during the
welding process.
Virtually test and evaluate different variable
without and avoid extremely expensive real
tryouts.

Sr. No.: 1 Title: Thermal Simulation of welding process using
ANSYS
Authors:
D.h.tailor,M.S.M.panwala,
S.A.Channiwala,K.A.Srinivasan
Years of
Publication:
2010
Name of Publisher:
Research Gate
Name of journal:
Thermal Simulation of welding
process using ANSYS
Topic Covered:
• Introduction of welding
• Objectives of present study
• Modeling of welding
Abstract: Temperature distribution that occurs during welding plays
major factor for the microstructure, mechanical properties and
the residual stresses in welded component.Estimation of correct transient
temperature distribution holds the key of accurate evaluation of weld induced residual
stresses.
Experimental, Analytical and Software Aspects: ANSYS Software
Conclusion: Numerical values of Peak temperature by using Gaussian heat input
model shows good agreement with experimental result with given heat input.It is
observed that predicted temperature qualitatively follows the experimental results
within -11.72 % to 3.2 %. Thus, such FEA model in ANSYS can be used in
manufacturing industries to investigate the temperature profile during the welding
which is source of residual stresses.

Sr. No.: 2 Title: Finite element analysis of welded structures
Authors:
Ramesh Sawant, Sachin Awasare
and Asokendu Samanta
Years of
Publication:
2007
Name of Publisher:
Ansys India Conference,
Bangalore
Name of journal:
Finite element analysis of welded
structures
Topic Covered: Welded structure; Finite
element method; Transient thermal
analysis; Temperature distribution
Abstract: In this paper attempts have been made to determine temperature
distribution due to welding by finite element method in welded panel structures. The
scope of present study is primarily limited to predict the temperature distribution
developed in butt and fillet welded panel structures only and temperature profiles
are presented. Good agreement of temperature profiles with existing literatures
validates the efficacy of the present methodology.
Conclusion : A 3-D finite element analysis has been carried out using ANSYS
software to determine temperature profile due to welding. Maximum temperatures
in both the cases are matching well with the existing results. This is due to the
assumptions that are made in the present analysis, as all the data are not available in
the literatures.

Sr. No.: 3 Title : Analysis of Welding Joints and Processes
Authors:
Akash Srivastava,Sumeet Sekhar,
Prayash rai, Ayush pandey
Years of
Publication:
2016
Name of Publisher:
International Conference on
Advances in Emerging
Technology
Name of journal: Analysis of
Welding Joints and
Processes
Topic Covered:
Welding joint, Strength, Arc Welding, Bending
Moment of welding joint, Deflection, Universal
testing machine
Abstract: The strengths of these joints are of great concern as in today’s world these
joints find a very crucial place in growths of structures and machine parts and it is the
strength of such joints and welding which decides the service life of such structures
and thus prevent from loss whether be it human loss, economic loss or the any such
losses.
Experimental, Analytical and Software Aspects:
Conclusion:. In present era it is necessary to build or create such type of joints
which are heavy duty and durable for a long period of time so that prevent from any
type of tragedy and to get maximum possible strength.
So we have done number of experiment for welding strength of mild steel to get the
right one method for different type of joints.

Sr. No.: 4 Title: 3D simulation of residual stress developed during TIG
welding of stainless steel pipes
Authors:
Varma Prasad V.M.a, Joy Varghese
V.M,Su.resh M.R.b,siva Kumar D.b
Years of
Publication:
20
Name of Publisher:International
Conference on Emerging Trends in
Engineering, Science and Technology
Name of journal:
3D simulation of residual stress developed during
TIG welding of stainless steel pipes
Topic Covered:
• Physical modeling
• Thermal analysis
• Mechanical analysis
Abstract: This paper deals with the effects of weld parameters on residual stress
developed during TIG welding of pipes. Due to non-uniform distribution of plastic and
thermal strains in and around the weld pool, large amounts of residual stresses and
deformations are present in all welded structures.
Conclusion: During the cooling phase due to the shrinkage and deformation in the weld zone
a high compressive stress is developed on the outer surface and a tensile residual stress is
developed on the inner surface. That is, from outer surface to inner surface the nature of residual
stress changes from compressive to tensile. X Axial residual stress variation along the thickness
has much importance in designing the pressure vessels and piping. Residual stress changes from
compressive to tensile from outer to inner surface after the welding, and at a particular point it
diminishes completely.

Sr. No.: 5 Title: Finite Element Simulation of Welding Distortion
in Dissimilar Joint by Inherent
Deformation Method
Authors: Mehdi Farajpour,
Eslam Ranjbarnodeh
Years of Publication:
2018
Name of Publisher:
Soldagem & Inspeção.
Name of journal: Finite Element
Simulation of Welding Distortion in Dissimilar
Joint by Inherent Deformation method
Topic Covered: Fem simulation;
Inherent deformation; Dissimilar joint;
Solid element; Shell element.
Abstract: Fusion welding is widely used to join different parts to each other in various
industries.Thus, it is imperative to predict and mitigate these problems to improve
weldment quality and also reduce fabrication costs. Afterwards, the constructed
weldment was simulated using an inherent deformation method, and its results were
compared with experimental measurements and 3D answers.
Conclusion: Elements, which needs a large memory as well as a time-consuming
analysis. Nevertheless, simulation with the inherent deformations uses 4-node shell
elements, reducing the required memory and the time needed for analysis. Empirical
results show that the distortion is 5.

Sr. No.: 6 Title: Simulation of TIG Welding Process
Authors:
Prof. Dr. P. Ravinder Reddy
2014
Name of Publisher:
LAP LAMBERT Academic
Name of journal:
Simulation of TIG Welding Process
Topic Covered:
 Welding Overview
Finite Element Analysis
Modeling of TIG Welding using FEA
Abstract: During the course of the Welding, high residual stress and distortion often
occur. This causes the problem in nuclear power plant components especially where the
danger of stress corrosion cracking (SSC) exists. In this study, both experimental and the
finite element methods (FEM) are utilized to investigate the welding residual stress
distribution in medium thick-walled austenitic stainless steel plates. A 10mm thick SS 316
plate of dimensions 300*150mm with TIG welding is selected as experimental
investigation and combination of FEM analysis using ANSYS software to predict the
temperature variation and thermal stresses with varying plate thickness, voltage and
efficiency factor.
Conclusion: Analysis of weld joint gives useful information for the modeling of the
process under different process conditions without carrying out real experiments on the
machine, this saves money, time and resources.

Sr. No.: 7 Title: Finite Element Modeling and Simulation of Welding of
Aerospace Components
Authors:
Andreas Lundback
2003
Name of Publisher:
Lulea University of Technology
Name of journal:
Licentiate Thesis
Topic Covered:
 Welding in Aerospace Engineering
Simulation Of Welding
Abstract: Fusion Welding is one of the most used method for joining metals. This method is largely
been developed by experiments. The problem of distortion and residual stresses of a structure due
to welding is important to control. This is especially important in the aerospace industry where the
components are expensive and safety and quality are highly important issues. The aim of the work
presented in this thesis is to develop an efficient and reliable method for simulation of the welding
process using the FEA. When creating the numerical model, the aim is to implement the physical
behavior of the process into the model. However, it may be necessary to compromise between
accuracy of the model and the required computational time.
Experimental, Analytical and Software Aspects: CAD Software, FEA Software
Conclusion: In this thesis, the meaning of efficiency of a model is wider than just the
computational efficiency. The time for creation and definition of the model should also be included.
Therefore a method for alleviating the tedious and time consuming pre-processing work of defining
the weld path is developed. Not only the position of the heat source is defined with this method,
also the element deactivation and activation is automatically controlled via the weld path. Moreover,
preliminary tests have been done using the rezoning technique. In these tests the position of the
locally refined area where also defined using the weld path.

Sr. No.: 8 Title: Simulation based numerical optimization of arc welding
process for reduced distortion in welded structures
Authors:
M. Islam, A. Buijk, M. Rais-Rohani, K.
Motoyama
2014
Name of Publisher:
Elsevier
Name of journal:
Finite Elements in Analysis and Design
Topic Covered:
Finite element modeling and welding simulation
Abstract: This paper presents an effective numerical approach for welding process parameter
optimization to minimize weld-induced distortion in structures. A numerical optimization framework
based on coupled Genetic Algorithm (GA) and Finite Element Analysis (FEA) is developed and
implemented for a low and a high fidelity model. The optimization results show that the proposed
approach can contribute substantially to enhance final welded product quality while facilitating and
accelerating the product design and development.
Assumptions: Classical weakly coupled thermo-mechanical analysis with thermo-
elesto-pastic assumptions is carried out for distortion prediction of numerical models.
Experimental, Analytical and Software Aspects:
Conclusion: In this context, this study introduced a robust numerical optimization
system based on integrated computational tools, which allow automatic optimization of
welding process parameters without the requirement of expensive experiments. The
system is capable of exploring the effect of several design variables at a time with limited
modification of the simulation model.

Sr. No.: 9 Title: Friction model for friction stir welding process simulation:
Calibrations from welding experiments
Authors:
Mohamed Assidi, Lionel Fourment,
Simon Guerdoux, Tracy Nelson
2010
Name of Publisher:
Elsevier
Name of journal:
International Journal of Machine Tools & Manufacture
Topic Covered:
Friction stir welding simulation
Abstract: According to the extreme encountered conditions and the highly coupled
nature of the material flow, simple tribological tests are not representative enough, so the
welding process itself has been utilized in most analysis of the literature, although its
complexity has led to use simplified numerical models and approaches. The main feature
of the numerical approach is to accurately compute the contact and frictional surface
between the plate and the tool.
Experimental, Analytical and Software Aspects: Abaqus, Langrangian, Simulation
Conclusion: The first conclusion of this work is that, in spite of the inherent difficulties to model
friction stir welding and to find coefficient values of the different thermo-mechanical model, the 3D
numerical results obtained with the developed arbitrary Lagrangian Eulerian formulation are in good
agreement with the measured forces and tool temperatures, independently of the utilized friction
model. Regarding the core of study, the calibration of a friction model, noticed that welding forces
and tool temperatures are highly sensitive to small variations of friction, which allows accurate
identification/calibration of the friction coefficients.

Sr. No.: 10 Title: Numerical Simulation of Welding Process – Application in
Buckling Analysis
Authors:
Denes Kollar, Balazs Kovesdi,
Janos Nezo
2017
Name of Publisher:
Creative commons Attribution
Name of journal:
Periodica Polytechnica Civil Engineering
Topic Covered:
Welding Simulation
Abstract: Numerical simulations make the improvement of fabrication process and welding
technology. Numerical simulations make the improvement of fabrication process and welding
technology possible. Using finite element method the most important information about welded
specimens can be determined such as deformed shape, residual stresses or even micro structural
properties like phase proportions or hardness. The current study focuses on the modeling
background of welding processes and the effects of different welding parameters on residual stresses
and deformations. The paper focuses on heat sources, temperature dependent material properties
and the development of a thermo-mechanical analysis. The virtually fabricated specimens are further
analyzed to investigate the stability behavior.
Experimental, Analytical and Software Aspects: SYSWELD , ANSYS
Conclusion: Nowadays the numerical modelling makes it possible to simulate the welding process
and to determine the residual stresses and the deformation of structures due to the manufacturing
procedure. To be able to model different welding processes a common heat source is developed in
ANSYS. The applied heat source and the material model are verified by independent software tool
and by own experiments.

Sr. No.: 11 Title: Numerical Simulation of Welding Distortion in
Largest Structure
Authors:
Dean Deng
2007
Name of Publisher:
H. Murakawa
Name of journal:
Computer method in applied in mechanics
and engineering
Topic Covered:
 Welding Distortion
Interface Elements
Inherent Deformation
Numerical Simulation
Abstract: Welding is a crucial manufacturing process and widely used in industries to
assemble various products including ships, automobiles , trains and bridges. prediction
and reduction of welding distortion are critical to improve the quality of welded
structures. Welding distortion during the assembly process is affected not only shrinkage
but also root gap and misalignment between parts to be welded.
Conclusion: It is gives useful information for the modeling of the process by this paper
it is save time and money. We can analysis without real experiment.

Sr. No.: 12 Title: Modeling and simulation of a heat source in
electric arc welding
Authors:
Isabelle Choquet
2011
Name of Publisher:
Prof. Jacques Aubreton
Name of journal: Modeling and
simulation of a heat source in electric arc
welding.
Topic Covered:
Electric arc welding
Distribution of thermal energy
Electric heat source
Abstract: This study focused on the modeling and simulation of a plasma heat source
applied to electric arc welding. The heat source was modeled in three space dimensions
coupling Two approaches were considered for calculating the magnetic field: i) three-
dimensional, and ii) axi-symmetric. thermal fluid mechanics with electromagnetism.
Experimental, Analytical and Software Aspects: CFD software
Conclusion: This study focused on the modeling and simulation of an electric arc heat
source in three space dimensions, coupling thermal fluid mechanics with
electromagnetism. Two approaches were considered for calculating the magnetic field
(i) three-dimensional (ii) axi-symmetric.

Sr. No.: 13 Title: Modeling of arc welding process
Authors:
Yoshinori Hirata
2012
Name of Publisher:
Springer, Tokyo
Name of journal:
Modeling and simulation of a heat source
in electric arc welding
Topic Covered:
 molding
Heat input distribution
Physical property
Abstract: 3D-Numerical model is described, which predicts transport phenomena in the
arc plasma and the weald pool associated with the arc welding process. Governing
equation and boundary condition are presented for obtaining time dependent behavior
of both thermal and electromagnetic fluid of gases plasma and liquid molten metal.
Conclusion: It is give useful information of the molding of the process .we can easily
conclude that account temperature dependencies of physical properties of shielding gas
and metal used for base material at relevant temperature .

Sr. No.: 14 Title: 2D and 3D Numerical Simulation of Tig Welding
(SS-316L) steel sheet.
Authors:
Lindgreen , Lars-Erik
2012
Name of Publisher:
Lionel Depradux &Jean-
Francois Jullien
Name of journal:
2D and 3D Numerical Simulation of Tig
Welding
Topic Covered:
 Finite Element Analysis
 2D Welding Simulation
 3D Welding Simulation
Abstract: In this study, a numerical simulation to predict residual stresses and
distortion generated by a TIG welding process is presented. 3D numerical
simulations have been performed on an instrumented test involving a fusion line
along the long axis direction of a 316L plate. the relevance of a simplified 2D-
plane stress modeling of this test case, for the prediction of residual stresses, is
discussed.
Conclusion: After read this paper we can easily say that stress distortion in tig welding
process . For the transient thermal analysis, the heat input modeling will callibrated
against thermocouple measurements.

Sr. No.: 15 Title: Arc Welding From Process Simulation to
Structural Mechanics
Authors:
Spille Kohoff
2009
Name of Publisher:
Munich
Name of journal:
Dr CFX Berline
Topic Covered:
Process Simulation with ANSYS CFX
Abstract: Arc welding and plasma cutting are widely used techniques to join or separate
metals. Though these methods have been in use for decades, there is not much theoretical
knowledge about the details of the actual physical processes. Significant empirical
experience exists, and simulation tools have been used to examine the stress or
deformation of the metal from an equivalent heat source representing the influence of the
electric arc. Most of this expertise and simulation is limited to well-known standard welding
processes.
Experimental, Analytical and Software Aspects: GmbH Software
Conclusion: The process simulation of arc welding for GMAW, GTAW or PAW, from basic physical
relations has been developed in the last 8 years towards a high agreement with measurements. ANSYS
CFX as CFD tool was extended by further models for electromagnetic and arc physics to get a
simulation tool for the multi-physics welding process in one software. With this tool, lots of electric arc
simulations have been done to get information on • arc stability and behavior, • heat input into the
electrodes and towards the cooling cycle.

Sr.
No.
Title Inventor Patent No. Year Country
1 Heat energy sensing
and analysis for
welding process
Thomas ignatowaski,
Micheal a. Nallen
US201501342
92A1
2015 United
States
2 Method and system for
modeling Spot welds in
a finite element
Analysis
Emily Nutwell, Dublin,Duane
Detwiler, Powell, john O. Hallquist, L
ivermore, CA
US007640142
B2
2009 United
States
3 Virtual testing and
inspection of a Virtual
weldment
Matthew waynewallace,
South windsor, ct (us); carl
Peters, solon, oh (us)
US201400655
84A1
2014 United
States
4 Systems and methods
providing Enhanced
education and training
in
A virtual reality
environment
Carl peters, solon, OH (US); deanna
Postlethwaite, chagrin falls, OH (US);
Matthew wayne wallace, south
Windsor, CT (US)
US
20140234813
A1
2014 United
States
5 Portable virtual
welding system
Deanna Postlethwaite, Chagrin Falls,
OH (US); Matthew Wallace, South
Windsor, CT (US); Jason Leach,
Cleveland Heights, OH (US);
Antonius
Aditjandra, Chardon, OH (US)
US
2015024884
5 A1
2015 United
States

Sr.
No.
1 Virtual testing and analysis of
virtual welds
Wallace,
Matthew, Wayne
Peters, Karl
JP5842055B2 2012-
2013
Japan
2 Finite element modeling
method for weld nut based
on automobile fatigue
simulation
Li Tianbing, Lian
Zhibin, Yang Han,
Xu Chengmin
CN107563072B 2017 China
3 Systems and methods of
providing enhanced
education and training in
virtual reality environment
Peters Carl,
Postlethwaite
Deanna, Wayne
Wallace Mathhew
JP2018185543A 2014-
2018-
2019
Japan
4 Virtual testing and inspection
of virtual weldments
M. W. Wallance, C
Peters
CN106057026B 2011 China
5 Systems and methods of
providing enhanced
education and training in
virtual reality environment
Carl Peters,
Denna
Postlethwaite,
Mathhew Wayne
Wallace
US9965973B2 2013-
2014-
2016-
2018
US

Sr.
No.
1 Welding training system and
device
William J. Becker US20140263224
A1
2013-
2017
US
2 Arc welding simulator trainer Harvey B Schow ,
Macy L Abrams
US3867769A 1973-
1992
US
3 Virtual reality GTAW and pipe
welding simulator and setup
Mathew Wayne
Wallace David
anthony ZBORAY ,
Antonius
Aditjandra, Adam
Lee Webb
US8851896B2 2013-
2014
US
4 Welding analysis using laser
generated narrowband lamb
waves
Ifeanyi Charles
Ume , Tsun-Yen
Wu
US9201046B2 2011-
2015
US
5 Arc welding quality evalution
apparatus
Yukimitsu suzuki US6703585B2 2001-
2004
US

Out Come
By this Project;
 We can reduce the time welding testing
experiments.
 We can reduce the cost of materials which are very
expensive.
 We can reduce the waste of the material which are
used in welding .

Learning From The Project
 How to use Software for welding analysis like
ANSYS and Simufact.
 How to calculate welding temperature, speed
of welding Torch, Etc.
 How to reduce the cost and wastage of
welding material.

PMMS Portal Entry Status
 Periodic Progress Report: First PPR :. Submitted

Work Plan
Jun July Aug Sep Oct
PPR-1
PPR-2
PPR-3
PPR-4
DE canvas
PSAR-1
PSAR-2
PSAR-3
PSAR-4
PSAR-5
Plagiarism Report
Novelty Search Report
Project Report
Completion Certificate

Welding Simulation Analysis

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