Computational Tools for the Numerical Simulation of Welding Processes.

This paper discusses various computational tools developed for the numerical simulation of welding processes. The tools can be broadly classified into two groups: Process related tools that facilitate simulation accuracy; Speed and ease-of-use related tools that facilitate simulation and operational efficiency. Process related tools that are discussed include the weld heat flux specification, the weld path and weld fillers that are created in conjunction with the moving heat source. Some of the issues associated with the weld heat flux computation are: correct choice of weld flux expression depending on the type of welding process; an appropriate scaling of heat input for 2D finite element simulations and an accurate numerical integration of the weld heat flux expression. Some of the issues associated with the weld path computation are: Options necessary for accurate and convenient specification of the weld path and arc orientation and the calculation of the local coordinate system of the moving source. Some of the issues associated with the weld filler element computation are: techniques available for the treatment of weld fillers in an analysis; boundary conditions for filler elements and multi-pass welds. Speed and ease-of-use related tools that are highlighted include parallel welding computations using the domain decomposition technique, local adaptive meshing schemes, 2D to 3D state variable transfer and global — local structural zooming. This paper describes several algorithms that have been recently developed and implemented in the commercial, non-linear finite element software MSC.Marc. © 2004 American Institute of Physics [ABSTRACT FROM AUTHOR]