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    Mid Sem Presentation

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    sahilnagula0504
    The document discusses modelling the melt pool during welding. It describes setting up governing equations to model temperature distribution, velocity, pressure and incorporate effects like Marangoni and buoyancy. Work done includes solving sample problems to obtain velocity, pressure and temperature plots in 2D and 3D. Remaining work is to consider combined heat transfer and introduce buoyancy effect.

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    Mid Sem Presentation

    Uploaded by

    sahilnagula0504
    11 views28 pages
    The document discusses modelling the melt pool during welding. It describes setting up governing equations to model temperature distribution, velocity, pressure and incorporate effects like Marangoni and buoyancy. Work done includes solving sample problems to obtain velocity, pressure and temperature plots in 2D and 3D. Remaining work is to consider combined heat transfer and introduce buoyancy effect.

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    The document discusses modelling the melt pool during welding. It describes setting up governing equations to model temperature distribution, velocity, pressure and incorporate effects like Marangoni and buoyancy. Work done includes solving sample problems to obtain velocity, pressure and temperature plots in 2D and 3D. Remaining work is to consider combined heat transfer and introduce buoyancy effect.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    11 views28 pages

    Mid Sem Presentation

    Uploaded by

    sahilnagula0504
    The document discusses modelling the melt pool during welding. It describes setting up governing equations to model temperature distribution, velocity, pressure and incorporate effects like Marangoni and buoyancy. Work done includes solving sample problems to obtain velocity, pressure and temperature plots in 2D and 3D. Remaining work is to consider combined heat transfer and introduce buoyancy effect.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 28

    MODELLING THE MELT POOL

    OF WELDING
    GROUP MEMBERS:
    SAHIL NAGULA B201210ME GUIDED BY
    YEKESH TADIKONDA B201186ME DR.VINEESH
    K.P
    KARANAM UMA MAHESWAR B201200ME
    CHANVITH REDDY DEVIREDDY B201194ME
    SHREYASH ASHOK SALUNKHE B201213ME
    INTRODUCTION
    • Current FEM solvers won’t consider the liquid
    part in the melt pool, but we consider the liquid
    part in the melt pool by including the
    convection term to accurate the temperature
    distribution inside the melt pool compared to
    FEM solvers.
    • The Effects to be considered :
     Maragoni Effect
     Bouyancy Effect

    Fig1 Temperature v/s time


    OBJECTIVE

    • Development of python code to predict the temperature distribution inside the


    melt pool during welding and manufacturing process.

    • Incorporate the effect of surface tension gradient (Marangoni effect) and


    buoyancy effect to estimate heat loss from the melt pool.
    LITERATURE REVIEW

    Title of the paper Author Major findings

    Modeling of heat transfer and Zhang, W., Roy, G.G., Elmer, J.W. To understand the importance of
    fluid flow during gas tungsten and DebRoy, T. heat transfer by conduction and
    arc spot welding of low carbon convection through various stages
    steel

    An improved prediction of Mukherjee, T., Zhang, W. Material properties and heat


    residual stresses and distortion source conditions
    in additive manufacturing
    WORK BRIEFING

    • Governing equations-
    1)Navier stokes equation.

    2) Continuity equation.
    WORK BRIEFING
    Continuity and Navier Stokes Equation
    For obtaining velocity plot
    (Mass and force conservation)

    Heat Source For Initial Temperature plot

    For effective Temperature after


    Energy equation and Marangoni Effect
    some time
    SUMMARY OF WORK PRESENTED
    • Executed a code for
    obtaining velocities using
    continuity and Navier Stokes
    equation
    • For that we have considered
    a standard Lid Driven Cavity
    problem
    • Solved it using Finite
    Difference Method

    Fig.2 Velocity Plot


    SUMMARY OF WORK PRESENTED
    • Executed a code for proving Marangoni effect in 2D scenario

    Fig3 Temperature plot Fig4 Velocity plot


    WORK DONE SINCE LAST PRESENTATION
    TILL NOW

    • Executed a code for velocities in 3D scenario using continuity and


    Navier Stokes equation
    • Executed a code for generating a heat source
    • Proving the Marangoni effect in 3D case as well as in 2D case considering the
    heat source.
    Creating a staggered grid

    Inducing velocity and pressure

    Continuity eqn Momentum eqn

    Updating the values

    No
    Verifying Boundary Conditions No

    Solution convergence

    Results plotting

    END
    WORK DONE DETAILS 1
    • Solved a basic LID driven cavity problem by giving an initial velocity at the top surface
    and obtained velocities and pressures using Continuity and Navier Stokes Equation

    Fig5 Velocity Plot Fig 6 Pressure Plot


    WORK DONE DETAILS 1

    • Observation-

    • There is a pressure difference observed inside the lid and no pressure


    difference across the edges.
    • There will be a turbulence induced inside due to pressure difference .
    • The results are observed as soon as the initial condition of velocities are given.
    WORK DONE DETAILS 2
    • For Generating Heat source
    Creating a Staggered Grid

    Considering the size and shape of the heat source

    Maximum Temperature of the heat source and edge temperature

    2*distance<size
    YES
    Maximum Temperature decreases exponentially NO

    Edge Temperature decreases exponentially

    END
    WORK DONE DETAILS 2
    • Executed a code for generating heat source in 2D scenario

    Fig7 Temperature plot in 2D


    WORK DONE DETAILS 2
    • Executed a code for generating heat source in 3D scenario considering a
    Elliptical Heat Source

    Fig8 Heat source at the centre of the cube Fig9 Heat source at the edge of the cube
    WORK DONE DETAILS 2
    • Executed a code for generating heat source in 3D scenario considering a
    Square Heat Source

    Fig10 Heat source at the centre of the cube Fig11 Heat source at the edge of the cube
    WORK DONE DETAILS 2
    • Observations-

    • Inside the heat source the temperature decreases exponentially along distance from the
    mentioned maximum temperature
    • Outside the heat source the temperature decreases exponentially along distance from the
    mentioned edge temperature
    • The temperature is maximum at the centre of the heat source
    • The temperature decreases exponentially along the depth as well
    WORK DONE DETAILS 3

     Properties of the material

    PROPERTIES TI-6AL-4V (MATERIAL)

    LIQIDUS TEMPERATURE(K) 1928

    THERMAL CONDUCTIVITY(W/MK) 1.57

    SPECIFIC HEAT(J/KGK) 492.4

    DENSITY(KG/M^3) 4000

    VISCOSITY(KG/M S) 0.004

    SURFACE TENSION GRADIENT(N/M^2) -0.00037


    WORK DONE DETAILS 3

     Process parameters used for heat source

    PARAMETER VALUE
    LASER POWER(W) 2000

    MAXIMUM TEMPERATURE(K) 3000

    TIME STEP(Sec) 10
    WORK DONE DETAILS 3

    • General Energy Equation-

    • Discretized Energy Equation-


    WORK DONE DETAILS 3

    • Marangoni effect equation-

    Discretised equation of the above Marangoni effect-


    Creating a staggered grid

    Inducing velocity temperature and pressure

    Continuity eqn Momentum eqn Energy eqn

    Updating the values

    No
    Verifying Boundary Conditions No

    Solution convergence

    Results plotting after 10 seconds

    END
    WORK DONE DETAILS 3
    Marangoni effect in 2D case

    Fig 14. Temperature plot at t=0 for 2D case Fig 15. Temperature plot at t=10 sec for 2D case
    WORK DONE DETAILS 3
    Marangoni effect in 3D case

    Fig12 Temperature plot at t=0 sec Fig13 Temperature plot at t=10 sec
    WORK REMAINING

    • Obtaining the temperature by considering the combined heat transfer through


    both conduction and convection
    • Introducing the effect of Buoyancy effect into the code
    CONCLUSION

    • The mass transfer will be from the center of the melt pool to the boundary side
    due to surface tension gradient present inside the melt pool.
    • The variation of temperature from the center to the boundary is in decreasing
    trend so the mass transfer will be from the center of melt pool to the boundary
    side.
    • Liquid consideration helps to consider the convection flow as well in the melt
    pool which helps to predict the temperature much more accurately.
    REFERENCES

    • Mukherjee, T., Zhang, W. and Debroy, T., 2017. An improved prediction of


    residual stresses and distortion in additive manufacturing. Computational
    Materials Science, 126, pp.360-372.
    • Zhang, W., Roy, G.G., Elmer, J.W. and DebRoy, T., 2003. Modeling of heat
    transfer and fluid flow during gas tungsten arc spot welding of low carbon
    steel. Journal of Applied Physics, 93(5), pp.3022-3033.
    THANK YOU!

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