A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications
During multidisciplinary design of welded aircraft components, designs are principally 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 experime...
| Main Authors: | , , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2019-06-01
|
| Series: | Aerospace |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2226-4310/6/6/74 |
| _version_ | 1818962904436703232 |
|---|---|
| author | Julia Madrid Samuel Lorin Rikard Söderberg Peter Hammersberg Kristina Wärmefjord Johan Lööf |
| author_facet | Julia Madrid Samuel Lorin Rikard Söderberg Peter Hammersberg Kristina Wärmefjord Johan Lööf |
| author_sort | Julia Madrid |
| collection | DOAJ |
| description | During multidisciplinary design of welded aircraft components, designs are principally 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 means welding producibility aspects are considered after the design has already been established. In 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. |
| first_indexed | 2024-12-20T12:36:44Z |
| format | Article |
| id | doaj.art-111689120609442182e8fe05c0cff8ff |
| institution | Directory Open Access Journal |
| issn | 2226-4310 |
| language | English |
| last_indexed | 2024-12-20T12:36:44Z |
| publishDate | 2019-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Aerospace |
| spelling | doaj.art-111689120609442182e8fe05c0cff8ff2022-12-21T19:40:35ZengMDPI AGAerospace2226-43102019-06-01667410.3390/aerospace6060074aerospace6060074A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace ApplicationsJulia Madrid0Samuel Lorin1Rikard Söderberg2Peter Hammersberg3Kristina Wärmefjord4Johan Lööf5Department of Industrial and Materials Sciences, Chalmers University of Technology, SE-412 96 Gothenburg, SwedenFraunhofer-Chalmers Research Centre for Industrial Mathematics, SE-412 88 Gothenburg, SwedenDepartment of Industrial and Materials Sciences, Chalmers University of Technology, SE-412 96 Gothenburg, SwedenDepartment of Industrial and Materials Sciences, Chalmers University of Technology, SE-412 96 Gothenburg, SwedenDepartment of Industrial and Materials Sciences, Chalmers University of Technology, SE-412 96 Gothenburg, SwedenGKN Aerospace Engine Systems, SE-461 38 Trollhättan, SwedenDuring multidisciplinary design of welded aircraft components, designs are principally 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 means welding producibility aspects are considered after the design has already been established. In 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.https://www.mdpi.com/2226-4310/6/6/74welding producibilitywelding simulationdesign of experimentsaerospace design for manufacturing |
| spellingShingle | Julia Madrid Samuel Lorin Rikard Söderberg Peter Hammersberg Kristina Wärmefjord Johan Lööf A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications Aerospace welding producibility welding simulation design of experiments aerospace design for manufacturing |
| title | A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications |
| title_full | A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications |
| title_fullStr | A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications |
| title_full_unstemmed | A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications |
| title_short | A Virtual Design of Experiments Method to Evaluate the Effect of Design and Welding Parameters on Weld Quality in Aerospace Applications |
| title_sort | virtual design of experiments method to evaluate the effect of design and welding parameters on weld quality in aerospace applications |
| topic | welding producibility welding simulation design of experiments aerospace design for manufacturing |
| url | https://www.mdpi.com/2226-4310/6/6/74 |
| work_keys_str_mv | AT juliamadrid avirtualdesignofexperimentsmethodtoevaluatetheeffectofdesignandweldingparametersonweldqualityinaerospaceapplications AT samuellorin avirtualdesignofexperimentsmethodtoevaluatetheeffectofdesignandweldingparametersonweldqualityinaerospaceapplications AT rikardsoderberg avirtualdesignofexperimentsmethodtoevaluatetheeffectofdesignandweldingparametersonweldqualityinaerospaceapplications AT peterhammersberg avirtualdesignofexperimentsmethodtoevaluatetheeffectofdesignandweldingparametersonweldqualityinaerospaceapplications AT kristinawarmefjord avirtualdesignofexperimentsmethodtoevaluatetheeffectofdesignandweldingparametersonweldqualityinaerospaceapplications AT johanloof avirtualdesignofexperimentsmethodtoevaluatetheeffectofdesignandweldingparametersonweldqualityinaerospaceapplications AT juliamadrid virtualdesignofexperimentsmethodtoevaluatetheeffectofdesignandweldingparametersonweldqualityinaerospaceapplications AT samuellorin virtualdesignofexperimentsmethodtoevaluatetheeffectofdesignandweldingparametersonweldqualityinaerospaceapplications AT rikardsoderberg virtualdesignofexperimentsmethodtoevaluatetheeffectofdesignandweldingparametersonweldqualityinaerospaceapplications AT peterhammersberg virtualdesignofexperimentsmethodtoevaluatetheeffectofdesignandweldingparametersonweldqualityinaerospaceapplications AT kristinawarmefjord virtualdesignofexperimentsmethodtoevaluatetheeffectofdesignandweldingparametersonweldqualityinaerospaceapplications AT johanloof virtualdesignofexperimentsmethodtoevaluatetheeffectofdesignandweldingparametersonweldqualityinaerospaceapplications |