Numerical simulation of droplet transfer process in ultrasonic-assisted MIG welding

Abstract

A numerical model of ultrasonic-assisted MIG welding droplet transfer was established, and ultrasonic vibration equation of motion was compiled by user-defined function. In several different transition modes, the comparison between the MIG and Ultrasonic-assisted MIG simulation results shows that the ultrasonic vibration makes the axial position of the welding wire shift during the droplet transition and promotes the droplet transition frequency more significantly in the droplet transition mode. Finally, the MATLAB image processing software is used to calculate the droplet size. The data comparison shows that the simulation results are in good agreement with the experimental results, which proves that the established numerical model is reasonable.

KEYWORDS:

• Numerical model
• ultrasonic-assisted MIG welding
• drop transfer
• image processing

Acknowledgements

The authors would like to thank the anonymous reviewers and editor.

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Funding

This work was supported by Key Laboratory of Lightweight and High Strength Structural Materials of Jiangxi Province: [Grant Number No. 20171BCD40003]; Key Laboratory of Nondestructive Testing Ministry of Education: [Grant Number No. EW201980090]; the Natural Science Foundation of China: [Grant Number No.51665037].