A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications
Journal article, 2019
optimized upon component performance, employing well-established modelling and simulation
techniques. On the contrary, because of the complexity of modelling welding process phenomena,much of the welding experimentation relies on physical testing, which meansĀ welding producibility aspects are considered after the design has already been established. InĀ addition, welding optimization research mainly focuses on welding process parameters, overlooking the potential impact of product design. As a consequence, redesign loops and welding rework increases product cost. To solve these problems, in this article, a novel method that combines the benefits of design of experiments (DOE) techniques with welding simulation is presented. The aim of the virtual design of experiments method is to model and optimize the effect of design and welding parameters interactions early in the design process. The method is explained through a case study, in which weld bead penetration and distortion
are quality responses to optimize. First, a small number of physical welds are conducted to develop and tune the welding simulation. From this activity, a new combined heat source model is presented.
Thereafter, the DOE technique optimal design is employed to design an experimental matrix that enables the conjointly incorporation of design and welding parameters. Welding simulations are then run and a response function is obtained. With virtual experiments, a large number of design and welding parameter combinations can be tested in a short time. In conclusion, the creation of a meta-model allows for performing welding producibility optimization and robustness analyses during early design phases of aircraft components
aerospace design for manufacturing
design of experiments
welding simulation
welding producibility
Author
Julia Madrid
Chalmers, Industrial and Materials Science, Product Development
Samuel C Lorin
Fraunhofer-Chalmers Centre
Rikard Söderberg
Chalmers, Industrial and Materials Science
Peter Hammersberg
Chalmers, Industrial and Materials Science, Engineering Materials
Kristina Wärmefjord
Chalmers, Industrial and Materials Science, Product Development
Johan Lööf
GKN Aerospace Sweden
Aerospace
2226-4310 (ISSN)
Vol. 6 6 74-Subject Categories
Aerospace Engineering
Manufacturing, Surface and Joining Technology
Vehicle Engineering
Areas of Advance
Production
Materials Science
DOI
10.3390/aerospace6060074