Nothing Special   »   [go: up one dir, main page]
Skip to main content
Springer Nature Link
Log in

Real-time simulation for a virtual reality-based MIG welding training system

  • SI: Manufacturing and Construction
  • Published:
Virtual Reality Aims and scope Submit manuscript

Abstract

This paper describes a real-time welding simulation method for use in a desktop virtual reality simulated Metal Inert Gas welding training system. The simulation defines the shape of the weld bead, the depth of penetration, and the temperature distribution in the workpiece, based on inputs from the motion-tracking system that tracks the position of the welding gun as a function of time. A finite difference method is used to calculate the temperature distribution, including the width of the weld bead and the depth of penetration. The shape of the weld bead is then calculated at each time step by assuming a semi-spherical volume, based on the width of the weld bead, the welding speed, and the wire feed rate. The real-time performance of the system is examined, and results from the real-time simulation are compared to physical tests and are found to have very good correlation for welding speeds up to 1,000 mm/min.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
$34.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or eBook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7

Similar content being viewed by others

Explore related subjects

Discover the latest articles, news and stories from top researchers in related subjects.

References

  • Aglawe A (2008) Virtual MIG welding simulation. M.S. Thesis, University of Louisiana at Lafayette, December, 2008

  • Chan B, Pacey J, Bibby M (1999) Modelling gas metal arc weld geometry using artificial neural network technology. Can Metall Q 38:43–51

    Article  Google Scholar 

  • Davoud MS, Deng X (2003) A comparison between three- and two dimensional thermal finite element analysis of the gas metal arc welding process. In: Proceedings of IMECE’03, Washington, DC, pp 123–130

  • Dorzin E (2003) Temperature of a MIG welder. In: Elert G (ed) The physics factbook. Available on-line at: http://hypertextbook.com/facts/2003/EstherDorzin.shtml. Accessed June, 2009

  • ETB (2005) Melting temperatures of some common metal and alloys. The engineering toolbox. Available on-line at: http://www.engineeringtoolbox.com/melting-temperature-metals-d_860.html. Accessed June, 2009

  • Fan HG, Kovacevic R (1998) Dynamic analysis of globular metal transfer in gas metal arc welding-a comparison of numerical and experimental results. J Phys D Appl Phys 31:2929–2941

    Article  Google Scholar 

  • Fast K, Gifford T, Yancey R (2004) Virtual training for welding. In: Proceedings of the third IEEE and ACM international symposium on mixed and augmented reality (ISMAR 2004), Washington, DC, pp 298–299. Symposium on Mixed and Augmented Reality. IEEE Computer Society, Washington, DC, 298–299. doi:10.1109/ISMAR.2004.65

  • Jones LA, Mendez P, Weiss D, Eager TW (1997) Dynamic behavior of gas metal arc welding. In: 9th Annual conference on iron and steel technology, Phoang, Korea

  • Kim IS, Basu A (1998) A mathematical model of heat transfer and fluid flow in the gas metal arc welding process. J Mater Process Technol 77:17–24

    Article  Google Scholar 

  • Kim G-H, Kang S-I, Lee S-B (1999) A study on the estimate of weld bead shape and the compensation of welding parameters by considering weld defects in horizontal fillet welding. In: Knowledge-based intelligent information engineering systems third international conference, pp 212–216

  • Kumar S, Bhaduri S (1994) Three-dimensional finite element modeling of gas metal-arc welding. Metallur Mater Trans B 25:435–441

    Article  Google Scholar 

  • Lee CK, Candy J, Tan CPH (2004) Measurement and finite element analysis of temperature distribution in arc welding process. Int J Comput Appl Technol 21(4):171–177

    Article  Google Scholar 

  • Mavrikios D, Karabatsou V, Fragos, Chryssolouris G (2006) A prototype virtualreality-based demonstrator for immersive and interactive simulation of welding process. Int J Comput Integr Manuf 19:294–300

    Article  Google Scholar 

  • Patankar SV (1980) Numerical heat transfer. Hemisphere, New York

    MATH  Google Scholar 

  • Porter NC, Cote J, Allan G, Timothy D, Lam W (2006) Virtual reality welder training. J Ship Prod 22:126–138

    Google Scholar 

  • Wang G, Huang PG, Zhang YM (2003) Numerical analysis of metal transfer in gas metal arc welding. Metallur Mater Trans B 34:345–353

    Article  Google Scholar 

  • White S, Prachyabrued M, Chambers TL, Reiners D, Borst C (2010) Low cost simulated MIG welding for advancement in technical training. Virtual Reality. Special Issue in Manufacturing and Construction. doi:10.1007/s10055-010-0162-x

  • WTIA (2006) Work instructions for macro examination of welds. Welding Technology Institute of Australia, Document no. TGN-RT-04. Available on-line at: http://www.wtia.com.au/pdf/TGN-RT-04%20Work%20Instruction%20for%20Macro%20Examination.pdf. Accessed June, 2009

  • Wu CS, Zhang MX, Li KH, Zhang YM (2007) Numerical analysis of double-electrode gas metal arc welding process. Comput Mater Sci 39:416–423

    Article  Google Scholar 

  • Zeng Z, Wang L, Wang Y, Zhang H (2009) Numerical and experimental investigation on temperature distribution of the discontinuous welding. Comput Mater Sci 44(4):1153–1162

    Article  Google Scholar 

  • Zhang W, Kim C-H, DebRoy T (2004) Heat and fluid flow in complex joints during gas metal arc welding-part I: numerical model of fillet welding. J Appl Phys 95:5210–5219

    Article  Google Scholar 

Download references

Acknowledgments

This work was funded by the Louisiana Workforce Commission, and their contribution is gratefully acknowledged.

Author information

Authors and Affiliations

  1. University of Louisiana At Lafayette, PO Box 42251, Lafayette, LA, 70504-2251, USA

    Terrence L. Chambers, Amit Aglawe & Abhishek Bajpayee

  2. Center for Advanced Computer Studies, University of Louisiana At Lafayette, Lafayette, LA, 70504, USA

    Dirk Reiners, Steven White, Christoph W. Borst & Mores Prachyabrued

Authors
  1. Terrence L. Chambers
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Amit Aglawe
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Dirk Reiners
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Steven White
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Christoph W. Borst
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Mores Prachyabrued
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Abhishek Bajpayee
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Terrence L. Chambers.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Chambers, T.L., Aglawe, A., Reiners, D. et al. Real-time simulation for a virtual reality-based MIG welding training system. Virtual Reality 16, 45–55 (2012). https://doi.org/10.1007/s10055-010-0170-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s10055-010-0170-x

Keywords

Search

Navigation