magnetohydrodynamicsandgas metal arcweldingin ansys fluent · magnetohydrodynamicsandgas metal...
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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
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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Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
Models needed for Gas Metal Arc Welding
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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GMAW
Flow Calculation
Gas Flow
Multiphase Flow
Magneto-hydrodynamics
Electro-magnetics
Forces
Energy Sources
Arc Modelling
Plasma Properties
Vapourization
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
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
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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Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
Multiphase Simulation
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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Vof function in flow field
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
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
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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Original phase interface
Interface Geo-ReconstructInterface Compressive
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
1.2 ms
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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experiment explicite implicite
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
3.5 ms
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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experiment explicite implicite
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
4.2 ms
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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experiment explicite implicite
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
Magnetohydrodynamics - Equations
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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Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
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
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
Electric Potential Method
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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MHD Motor with external magnetic field
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
Magnetic Induction Method
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Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
New Approach
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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Magnetic field due to current in conductor, „Right Hand Rule“
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
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
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
Simulation of welding processes
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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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
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
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
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
GMAW with multiphase
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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Simulation of a multiphase GMAW model, arc after ignition (left), arc after melting (right)
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
Influence of metal vapour
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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Simulation of a multiphase GMAW model considering metal vapour, arc after ignition (left), arc after melting (right)
Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
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
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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Fakultät Maschinenwesen IOF Professur Fügetechnik und Montage
Thank you for your attention
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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