Numerical simulation of electromagnetically driven flow in the weld pool during arc welding

A. Kumar, T. DebRoy

Research output: Contribution to journalConference article

1 Citation (Scopus)

Abstract

The electromagnetic force results from the interaction between the current flow and the induced magnetic field in the weldment. Comprehensive three-dimensional calculations of current flow and induced magnetic field are needed for accurate determination of the electromagnetic force. In the literature, several simplifying analytical expressions for the electromagnetic force have been suggested and widely used without any critical evaluation of their intrinsic merit, since accurate numerical calculations were difficult in the past because of lack of fast computers. With the advances in computational hardware and software, it is now possible to do relatively complex calculations that were much more difficult to perform just a few decades ago. The objective of the present investigation is to propose a mathematical model to numerically solve the electromagnetic force field in the weldment and determine the effect of commonly used simplifications on the accuracy of the calculated electromagnetic force field and weld pool temperature and velocity fields. A numerical model has been developed to accurately calculate the current density and magnetic flux fields and the resulting electromagnetic force field in three dimensions in the entire weldment. The computed electromagnetic force field was used in a 3-D heat transfer and fluid flow model to calculate the temperature and velocity distributions in the weld pool. The fusion zone geometry was experimentally measured for different current, voltage and arc power distribution. The agreements between the calculated and experimental FZ geometries indicate that the proposed numerical model gives accurate electromagnetic force distribution inside the workpiece.

Original languageEnglish (US)
Pages (from-to)833-842
Number of pages10
JournalAmerican Society of Mechanical Engineers, Fluids Engineering Division (Publication) FED
Volume259
DOIs
StatePublished - Jan 1 2003
Event2003 ASME International Mechanical Engineering Congress - Washington, DC., United States
Duration: Nov 15 2003Nov 21 2003

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Electric arc welding
Welds
Numerical models
Computer simulation
Magnetic fields
Geometry
Magnetic flux
Velocity distribution
Computer hardware
Flow of fluids
Temperature distribution
Current density
Fusion reactions
Mathematical models
Heat transfer
Electric potential
Temperature

All Science Journal Classification (ASJC) codes

  • Engineering(all)

Cite this

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abstract = "The electromagnetic force results from the interaction between the current flow and the induced magnetic field in the weldment. Comprehensive three-dimensional calculations of current flow and induced magnetic field are needed for accurate determination of the electromagnetic force. In the literature, several simplifying analytical expressions for the electromagnetic force have been suggested and widely used without any critical evaluation of their intrinsic merit, since accurate numerical calculations were difficult in the past because of lack of fast computers. With the advances in computational hardware and software, it is now possible to do relatively complex calculations that were much more difficult to perform just a few decades ago. The objective of the present investigation is to propose a mathematical model to numerically solve the electromagnetic force field in the weldment and determine the effect of commonly used simplifications on the accuracy of the calculated electromagnetic force field and weld pool temperature and velocity fields. A numerical model has been developed to accurately calculate the current density and magnetic flux fields and the resulting electromagnetic force field in three dimensions in the entire weldment. The computed electromagnetic force field was used in a 3-D heat transfer and fluid flow model to calculate the temperature and velocity distributions in the weld pool. The fusion zone geometry was experimentally measured for different current, voltage and arc power distribution. The agreements between the calculated and experimental FZ geometries indicate that the proposed numerical model gives accurate electromagnetic force distribution inside the workpiece.",
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AB - The electromagnetic force results from the interaction between the current flow and the induced magnetic field in the weldment. Comprehensive three-dimensional calculations of current flow and induced magnetic field are needed for accurate determination of the electromagnetic force. In the literature, several simplifying analytical expressions for the electromagnetic force have been suggested and widely used without any critical evaluation of their intrinsic merit, since accurate numerical calculations were difficult in the past because of lack of fast computers. With the advances in computational hardware and software, it is now possible to do relatively complex calculations that were much more difficult to perform just a few decades ago. The objective of the present investigation is to propose a mathematical model to numerically solve the electromagnetic force field in the weldment and determine the effect of commonly used simplifications on the accuracy of the calculated electromagnetic force field and weld pool temperature and velocity fields. A numerical model has been developed to accurately calculate the current density and magnetic flux fields and the resulting electromagnetic force field in three dimensions in the entire weldment. The computed electromagnetic force field was used in a 3-D heat transfer and fluid flow model to calculate the temperature and velocity distributions in the weld pool. The fusion zone geometry was experimentally measured for different current, voltage and arc power distribution. The agreements between the calculated and experimental FZ geometries indicate that the proposed numerical model gives accurate electromagnetic force distribution inside the workpiece.

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