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Chained simulation of the welding-forming process in analysing press force and geometrical deformation using non-linear numerical computation with experimental validation

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Abstract

This study discusses the development of a numerical simulation model to predict press force and final deformation induced by welding-to-forming process chain with experimental validation. The numerical models of welding and forming were developed in sequence by utilizing two specialized virtual manufacturing software family namely Simufact.Welding (SW) and Simufact.Forming (SF). In the non-linear thermomechanical simulation, the GMAW process was firstly executed on a butt joint of mild steel S235 with thickness of 2 mm followed by bending process whereby the plate and dies geometry were modelled based on the actual dimension and the weld bead geometry was modelled by means of simplified shape. The result of transient welding simulation was transferred to forming which considers the final deformation and effective stress. For achieving realistic transient temperature distribution, the heat transfer coefficients during the welding process were calibrated on specific points measured by using thermocouple with data logger. For verification purpose, a series of comprehensive welding experiments was executed using robotic system followed by the metal bending process using hydraulic press machine. It can be observed at the final deformation results that the difference between simulation using SF-SW and experiment showed an acceptable error percentage within the range of 4 to 12% on each measurement point and up to 7% in average. The press force prediction showed an error percentage of up to 10% at lower-to-medium and up to 17% at high stroke section. Hence, by referring to the results, this study can be applied to select a suitable press machine for this specific coupled process based on estimated load range.

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Acknowledgements

The authors would like to express their gratitude to staff members of Smart Manufacturing Research Institute (SMRI) and Research Interest Group: Advanced Manufacturing Technology (RIG:AMT) at School of Mechanical Engineering, Universiti Teknologi MARA (UiTM), Professorship of Virtual Production Engineering and Chair of Welding Engineering at Chemnitz University of Technology (CUT) in Germany for encouraging this research.

Funding

This research is financially supported by Fundamental Research Grant Scheme (FRGS) with Project Code: FRGS/1/2022/TK10/UiTM/02/84, Geran Konsortium Kecemerlangan Penyelidikan (Large Volume Additive Manufacturing/LVAM) from Ministry of Higher Education (MOHE) in Malaysia and DAAD Germany (Future Technology Additive Manufacturing) with Project Code: 57525437.

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Authors and Affiliations

  1. Smart Manufacturing Research Institute, UiTM Shah Alam, Selangor, Malaysia

    Mohd Shahriman Adenan, Keval P. Prajadhiana, Muhd Faiz Mat & Yupiter H. P. Manurung

  2. School of Mechanical Engineering, UiTM Shah Alam, Selangor, Malaysia

    Mohd Shahriman Adenan, Keval P. Prajadhiana, Muhd Faiz Mat & Yupiter H. P. Manurung

  3. Faculty of Industrial Engineering, University of Indonesia, Jakarta, Indonesia

    Dendi P. Ishak

  4. Faculty of Engineering, Universitas Indo Global Mandiri, Palembang, Indonesia

    Erry T. Adesta

  5. Professorship of Virtual Production Engineering, Chemnitz University of Technology, Chemnitz, Germany

    Pascal Colditz

  6. Design, Research, Extension in Additive Manufacturing, Advanced Materials and Advanced Manufacturing (DR3AM) Center, Bataan Peninsula State University, City of Balanga, Bataan, Philippines

    John R. C. Dizon

  7. Serba Dinamik Group Berhad, Shah Alam, Malaysia

    Mohamed Ackiel Mohamed

  8. Centre of Advanced Manufacturing & Material Processing (AMMP Centre), University of Malaya, Kuala Lumpur, Malaysia

    Mohd Fadzil Jamaludin

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  1. Mohd Shahriman Adenan
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Correspondence to Yupiter H. P. Manurung.

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Adenan, M.S., Prajadhiana, K.P., Mat, M.F. et al. Chained simulation of the welding-forming process in analysing press force and geometrical deformation using non-linear numerical computation with experimental validation. Int J Adv Manuf Technol 125, 4631–4646 (2023). https://doi.org/10.1007/s00170-023-11069-x

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