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Experimental And Numerical Analysis Of Temperature Distribution In Submerged Arc Welding Process

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Author(s): Ch.Indira Priyadarsini1, N.Chandra Sekhar2, Dr.N.V.Srinivasulu3

Journal: International Journal of Advanced Research in Computer Engineering & Technology (IJARCET)
ISSN 2278-1323

Volume: 1;
Issue: 6;
Start page: 033;
Date: 2012;
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Keywords: C - Specific heat | th e -Thermal expansion | f h-Convection heat transfer coefficient | k - Thermal conductivity | q- Heat flux | max q - Maximum heat flux | r -Distance from heat source centre | E - Modulus of elasticity | I –Current | [K] -Stiffness matrix | Q -Heat input | R-Radius of heating spot | T -Body Temperature | ¥ -T Surrounding temperature | U – Voltage | a -Thermal diffusivity | e -Strain / Thermal emissivity | s -Stress | y s -Yield stress | h - Arc efficiency | r- Density of the material | g-Poisson’s ratio

ABSTRACT
In large steel fabrication industries such as shipbuilding, and high-speed train guide way, the problem of residual stresses and overall distortion has been and continues to be a major issue. In the last few decades, various research efforts have been directed at the control of the welding process parameters aiming at reducing the distortions and residual stress effects. Yet, in actual practice, large amounts of resources are still being spent in reworking welds, which in turn increases the production cost and delays work completion. It is assumed that in order to reduce the residual stresses and distortions from a welding operation, it is necessary to understand the effects of welding process parameters on the responses. In this thesis, an experimental study has been conducted to assess the effects of heat input, speed rate, wire feed rate, plate thickness, and gap on arc welding responses as applied to steel welding. A butt joint Submerged Arc Welding has been chosen in this study. Submerged Arc Welding (SAW) uses the arc struck between a continuously fed additional filler metal under a blanket of granular flux. The thermal effect of Submerged Arc that specially depends on the electrical arc, flux type and temperature field of its work piece, is the main key of analysis and optimization of this process. The arc welding process is simulated using Finite Element Method (FEM) program ANSYS®. Thermal analysis is carried out and with the above load structural analysis is also performed for analyzing the stability of the structure.The simulations were carried out using a two-step process; non-linear heat transfer that produces the dynamic temperature distribution throughout the weld seam and the plates, and the elasto-plastic analysis, which yields residual stresses, strains, and displacement.Numerical simulation of welding process has been done by analysis tool ANSYS Relationships between the parameters and the responses have been drawn based on the simulation results as well as experimental results
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