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Tools for simulation based fixture design to reduce deformation in advanced fusion welding
University West, Department of Engineering Science, Division of Electrical and Automation Engineering. (PTW)ORCID iD: 0000-0001-5734-294X
University West, Department of Engineering Science, Division of Electrical and Automation Engineering. (PTW)ORCID iD: 0000-0002-4329-418X
University West, Department of Engineering Science, Division of Electrical and Automation Engineering. (PTW)ORCID iD: 0000-0001-5608-8636
University West, Department of Engineering Science, Division of Process and Product Development. (PTW)
2008 (English)In: Intelligent Robotics and ApplicationsLecture Notes in Computer Science Volume 5315,  2008: First International Conference, ICIRA 2008 Wuhan, China, October 15-17, 2008 Proceedings, Part II / [ed] Youlun Xioun, Springer, 2008, Vol. 5315 LNAI, no PART 2, p. 398-407Conference paper, Oral presentation only (Refereed)
Abstract [en]

The traditional fusion welding and fixture simulations are performed using advanced finite element simulation tools, commonly used are e.g. MSC.Marc, ANSYS, ABACUS and COMSOL Multiphysics. These simulations are made one at a time and separately due to heavy calculation load for each case. Such an approach does not give a full description of the integrated work piece and fixture behaviour. We propose a strategy to decrease the computational time and solve the problem accurately enough for industrial needs. Focus of the simulation result is on residual deformation. The work piece is a simplified component composed by metal sheets, and rigid and loose clamping was investigated. Simulation results give the size of forces and deformations in the clamped edge. Deformation measurements are performed using 3D-scanning of the work piece after cooling and released from fixture, same situation as in the FE-simulations. The proposed strategy has shown to be useful and is industrially competitive due to reduced engineering manpower, computation time, and need for practical experiments. The strategy is to use full off-line programming where computer aided robotics for weld sequencies is integrated with finite element modelling in order to obtain weld parameters and fixture design.

Place, publisher, year, edition, pages
Springer, 2008. Vol. 5315 LNAI, no PART 2, p. 398-407
Series
Lecture Notes in Computer Science, ISSN 0302-9743 ; 5315
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-1514DOI: 10.1007/978-3-540-88518-4_43OAI: oai:DiVA.org:hv-1514DiVA, id: diva2:216581
Conference
1st International Conference on Intelligent Robotics and Applications, ICIRA 2008; Wuhan; China; 15 October 2008 through 17 October 2008
Available from: 2009-05-11 Created: 2009-05-11 Last updated: 2016-02-11Bibliographically approved
In thesis
1. Simulation-based feedback control of welding processes
Open this publication in new window or tab >>Simulation-based feedback control of welding processes
2008 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Fusion welding for joining of metals is an important manufacturing process widely used in industry, and very appreciated for its usefulness. This thesis presents a strategy dealing with the problem of designing feedback control for robotised welding. The idea is to use off-line programming where computer aided robotics for weld sequences is integrated with finite element modelling for simulations and analyses of weld processes. By this approach the design, evaluations, trials and visualisation can be made “off-line”, beside or prior to continuous production. The focus is to reduce the amount of manpower and need for physical experiments. Focuses on the results are to ensure a high quality weld with limited residual stress and deformation. Different models for two types of austenitic steels and two types of weld sources has been calibrated and validated to form a basis for this strategy. Suggestions for systematic model calibration methods have been proposed including global and local optimisation methods. Experimental work has been performed to support and verify the simulation results and the usefulness of the method. The simulation based strategy has been evaluated and proven to work successfully in two different types of applications. The method is not independent of physical experiments since it is based on models that have to be calibrated, but the experiments needed are assumed to be carried out in a simple and cost efficient way. The thesis suggests how these experiments can be performed. The use of all these technologies is assumed to form an efficient tool for the welding engineer in order to obtain high weld quality in robotised welding. The research presented indicates that the methods work well in real situations and that further work for more robust industrialisation will be beneficial for the welding community.

Place, publisher, year, edition, pages
Göteborg: Chalmers University of Technology, 2008. p. 109
Series
Technical report / Department of Signals and Systems, Automation Research Group, Chalmers University of Technology, ISSN 1403-266X ; 2008:013
Keywords
Finite element modelling, Heat transfer, Model order reduction, Sensors, Weld simulation Controller design
National Category
Control Engineering
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-2409 (URN)
Presentation
2008-10-03, C120, Gustava Melins gata 2, Trollhättan, 10:15 (English)
Opponent
Supervisors
Available from: 2010-04-29 Created: 2010-04-29 Last updated: 2016-02-09Bibliographically approved
2. Modeling and simulation for welding automation
Open this publication in new window or tab >>Modeling and simulation for welding automation
2010 (English)Doctoral thesis, comprehensive summary (Other academic)
Place, publisher, year, edition, pages
Göteborg: Chalmers, 2010. p. 158
Series
Doktorsavhandlingar vid Chalmers tekniska högskola, ISSN 0346-718X ; 3132
Keywords
welding automation, fixturing, finite element modeling, heat conduction, model order reduction, sensors, welding simulation, controller design
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-2870 (URN)978-91-7385-451-1 (ISBN)
Available from: 2010-12-03 Created: 2010-11-29 Last updated: 2016-02-09Bibliographically approved

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Sikström, FredrikEricsson, MikaelChristiansson, Anna-Karin

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Sikström, FredrikEricsson, MikaelChristiansson, Anna-KarinNiklasson, Kjell
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