MagnetohydrodynamicsandGas Metal ArcWeldingin ANSYS Fluent · MagnetohydrodynamicsandGas Metal ArcWeldingin ANSYS Fluent M. Trautmann, M. Hertel, U. Füssel TU Dresden Institut für

Magnetohydrodynamics and Gas MetalArc Welding in ANSYS Fluent

M. Trautmann, M. Hertel, U. FüsselTU Dresden

Institut für FertigungstechnikProfessur für Fügetechnik und Montage

A. Spille-KohoffCFX Berlin Software GmbH

Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage


Motivation

• Numerical description ofelectromagnetics in ANSYS Fluent

• Simulation of welding processes− Extending process comprehension

• Multiphase simulation andelectromagnetics

− Welding processes considering material transition

04.07.2013 ANSYS Conference & 31ANSYS Conference & 31thth CADFEM Users' Meeting 2013CADFEM Users' Meeting 2013June 19June 19--21, 2013 21, 2013 –– Rosengarten MannheimRosengarten Mannheim

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Models needed for Gas Metal Arc Welding


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GMAW

Flow Calculation

Gas Flow

Multiphase Flow

Magneto-hydrodynamics

Electro-magnetics

Forces

Energy Sources

Arc Modelling

Plasma Properties

Vapourization


Agenda

• Simulation of multiphase flow− Volume of Fluid− PLIC and Compressive

• Magnetohydrodynamics in ANSYS Fluent− MHD-Module provided by ANSYS Fluent− Improved model

• Simulation of Welding processes− Comparison to ANSYS CFX− Multiphase welding process


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Multiphase Simulation


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Vof function in flow field


Implicite and explicite multiphase calculation

• Explizite− Fast and precise− Geometric phase interface

reconstruction possible(Geo-Reconstruct / PLIC)

− Small timestep• Implizite

− Large timestep− Compressive phase

interface calculation• Compared to experiments of

D. H. Peregrine


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Original phase interface

Interface Geo-ReconstructInterface Compressive


1.2 ms


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experiment explicite implicite


3.5 ms


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4.2 ms


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Magnetohydrodynamics - Equations


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Magnetohydrodynamics in Fluent


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Magnetohydrodynamics in Fluent

Magnetic InductionMethod

Equations formagnetic field

Boundaries:Magnetic boundary

condition

Electric Potential Method

Equation foreletric field

Boundaries:Electric boundary

condition


Electric Potential Method


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MHD Motor with external magnetic field


Magnetic Induction Method


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New Approach


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Magnetic field due to current in conductor, „Right Hand Rule“


Simulation of welding processes


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• Simplified GMAW process with solid geometry• Comparison to the MHD module in ANSYS CFX• Rotational symmetry

− 2D geometry in Fluent− 6° geometry in CFX

• Boundary conditions− Electric potential: 3 V− Gas flow rate: 12 l

OpeningNozzle

Inlet

Calculation area

CathodeAnode


Simulation of welding processes


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CFX Fluent

Current [A] 94.57 93.05

Force Workpiece[N] 0.0017747 0.001822

Ohmic Loss [W] 283.1 279.8

Power[W]= U*I

283.71 279.15

Resistance [Ohm] 0.0317 0.326

radiation [W] 153.8 155.2


Geometry multiphase GMAW


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opening

Inletshielding

gas

axis

cathode

InletWelding wire

20 mm

12 m

m

Wire electrode with temperature distributionCalculation area


GMAW with multiphase


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Simulation of a multiphase GMAW model, arc after ignition (left), arc after melting (right)


Influence of metal vapour


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Simulation of a multiphase GMAW model considering metal vapour, arc after ignition (left), arc after melting (right)


Conclusion and lookout

• Implementation of a new module for MHD• Successfully calculated welding arc• Welding arc combined with multiphase simulation• Considering vapourization for realistic temperature

distribution and droplet formation• Future:

− Coupled model with workpiece− Predict the impact of the plasma gas on the seam quality− Predict the impact of the power source on the seam quality


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Thank you for your attention


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Documents

MagnetohydrodynamicsandGas Metal ArcWeldingin ANSYS Fluent · MagnetohydrodynamicsandGas Metal ArcWeldingin ANSYS Fluent M. Trautmann, M. Hertel, U. Füssel TU Dresden Institut für