Process modelling and optimization of keyhole plasma arc welding of thin Ti-6Al-4V
Process modelling and optimization of keyhole plasma arc welding of thin Ti-6Al-4V
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DOI：
10.1177/0309324714524947
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发表时间：
2014-03
期刊：
影响因子：
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通讯作者：
Wei Sun;M. B. Mohammed;Lei Xu;T. Hyde;D. McCartney;S. Leen
中科院分区：
文献类型：
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作者：
Wei Sun;M. B. Mohammed;Lei Xu;T. Hyde;D. McCartney;S. Leen
本文介绍了一个全面的研究工作，重点是开发，验证和应用有限元建模能力的预测和优化的机器人小孔等离子弧焊的Ti-6Al-4V薄结构。进行了实验和计算研究，以表征，开发，优化和验证有限元建模的各个方面。实验研究包括使用机器人焊接单元确定焊接参数包络线和测量热历史、变形、残余应力和熔池轮廓。计算研究包括有限元模型的开发和验证以及使用遗传算法方法的全自动焊接序列优化工具的开发和验证。这项工作提供了有益的指导和通用方法，薄和复杂的轻质结构的优化设计，并形成了一个框架的发展基础上的结构完整性评估和组件寿命的薄结构焊接制造。优化工具具有被方便地修改以适合其他优化目标和/或焊接工艺的显著潜力。
This article presents a comprehensive piece of research work focused on the development, validation and application of finite element modelling capability for the prediction and optimization of robotic keyhole plasma arc welding of Ti-6Al-4V thin structures. Experimental and computational investigations were carried out to characterize, develop, optimize and validate various aspects of the finite element modelling. The experimental investigations cover the determination of welding parameter envelopes using a robotic welding cell and the measurements of thermal history, distortion, residual stress and weld pool profile. The computational investigations include the development and validation of finite element models as well as the development and validation of a fully automated welding sequence optimization tool using a genetic algorithm approach. The work provides useful guidance and generic methodologies for optimum design of thin and complex lightweight structures and has formed a basis for the development of a framework on structural integrity assessment and component lifing of thin structures fabricated by welding. The optimization tool has significant potential to be conveniently modified to suit other optimization objectives and/or welding processes.