Experiment and FEA simulation for predicting maximum distortion in the submerged arc welding process

This article investigates the influence of process and geometric parameters on deformation during mild steel Submerged arc welding (SAW). This article focuses on optimizing welding process parameters to reduce distortion and improve product quality. The intent of this study is to investigate the effects of technical and geometrical parameters on deformation during submerged arc welding of mild steel using ANSYS and experimental values employing element type brick 8 node 70. The temperature distribution was analyzed using the double ellipsoidal heat source model developed by Goldak, and the amount of deformation was predicted by changing the plate thickness, welding speed and current. The finite element method (FEM) was used to simulate the welding process and obtain an approximate solution. ANSYS software was used for modeling and analysis. The effect of four main parameters of the series (A, B, C, D) on the distortion was analyzed. The simulation results were compared with the experimental values. The study revealed that the maximum distortion determined for SET A was 1.341 mm, corresponding to the experimental value of 1.20 mm. SET B resulted in a maximum distortion of 0.88 mm, corresponding to an experimental value of 0.60 mm. The increase in heat-input in SET C increased the strain/distortion from 1.341 to 2.989 mm, which closely matches the experimental value of 2.60 mm. Increasing the welding speed for SET D reduces the deformation from 2.989 to 2.230 mm, in good agreement with the experimental value of 2.012 mm. SET E investigated the effect of different plate thicknesses on deformation, and the thicker the plate, the lower the maximum deformation. This research can aid in the optimization of welding process parameters and the reduction of distortion in the finished product by forecasting the maximum distortion by varying these parameters. The novelty of this study lies in its investigation of the influence of various variables on the welding process and the distortion that results, which has the potential to significantly enhance the welding process and the caliber of the final product. The findings of this study can be applied in the shipbuilding and automotive industries.