Professional Documents
Culture Documents
I.
INTRODUCTION
II.
MODELING OF ARC
A. Governing Equations
In GTA welding, the process usually uses a direct current
straight polarity. In this model, a tungsten electrode with a
diameter of 3.2 mm is used. The assumptions adopted for
modeling are summarized as follows.
(1) The arc is assumed to be pure argon in local thermodynamic equilibrium (LTE) and is assumed to be optically thin to radiation.
(2) The arc is steady and radially symmetric. For simplicity
of the analysis, the temperatures of the cathode and
anode are assumed to be constant.
(3) The arc plasma can be assumed to be a laminar flow.
Buoyancy and the heating effect of viscous dissipation
are negligible.
VOLUME 28B, AUGUST 1997679
The free-burning arc should be analyzed with a combined model of fluid mechanics and electromagnetics, and
satisfy a group of magneto-hydro-dynamics (MHD) equations. With the aforementioned assumptions, the conservation equations are expressed in terms of cylindrical
coordinates, as follows.
Equation of mass continuity:
](ru)
1 ](rrv)
1
50
r ]r
]z
[1]
[2]
1 ]
]u
]
]u
rruv 2 mr
1
ruu 2 m
r ]r
]r
]z
]z
]P
1 ]
]v
]
]u
52 1
(mr ) 1
(m ) 1 jr Bu
]z
r ]r
]z
]z
]z
[3]
Fig. 3Computational domain for welding arc.
Conversation of energy:
1 ]
k ]h
]
k ]h
rrhv 2 r
1
ruh 2
r ]r
Cp ]r
]z
Cp ]z
5
Under the axisymmetric cylindrical coordinate, the current continuity can be written in terms of the potential, as
follows:
j r2 1 j z2
5 Kb jz ]h
j ]h
2 SR 1
(
1 r
)
s
2 e CP ]z
CP ]r
[4]
]f
,
]r
jz 5 2s
]f
]z
[5]
]
]f
1 ]
]f
(s r ) 1
(s ) 5 0
r ]r
]r
]z
]z
[6]
m0
r
* j rdr
r
[7]
Table I.
AG or BG
GF
FE
ED
DA or BCD
u
v
h
]u/]r 5 0
v50
]h/]r 5 0
]f/]r 5 0
u50
v50
h 5 hconst
(T 5 1000 K)
f50
]u/]r 5 0
](rrv)/]r 5 0
h 5 hconst
(T 5 1000 K)
]f/]r 5 0
u 5 ugiven
v50
h 5 hconst
(T 5 1000 K)
]f/]z 5 0
u50
v50
h 5 hconst
(T 5 3000 K)
2s]f/]z 5 j0
Qr 5
p/2
* * * 4p{(r 2 r )
4Sr rl
du drdl
1 l2 1 4rr0 sin2 u}3/2
[10]
where H and R are the height and radius of the welding
arc, respectively. The geometric configuration for calculating Eq. [10] is shown in Figure 2. The heat transfer due to
the electron flow was calculated as follows.
Qc 5 ja (2.76 1 VW)
[11]
where ja is the current density into the base plate, the constant 2.76 is the approximating factor for the kinetic energy
of electrons assumed to be at 10,000 K, and Vw is the work
function of the base plate.
B. Calculation Domains and Boundary Conditions
[8]
v
0.515 mabrab 0.11
(
) (mara )0.5 (hab 2 ha)
Pra
mara
r
[9]
1 ]
]F
rrvF 2 rGF
r ]r
]r
]
]F
ruF 2 GF
5 SF
]z
]z
[13]
u52
Q
pr
ln (r/R2)
R 2 r 1 (R 2 R )
ln (R2 /R1)
2
2
2
2
R42 2 R41 1
2
1
(R22 2 R21)2
ln (R2 /R1)
[12]
III.
NUMERICAL PROCEDURE
A. Transformation
To solve the governing equations with the finite-difference method, the physical domain represented by a boundary-fitted coordinate system must be transformed into a
rectangular domain. Before applying the transformation, the
governing equations can be expressed in a generalized formula using a general dependent variable F, as follows.
]F ]z ]j
1 ]
]F ]j
rrvF 2 rGF (
1
r ]j
]j ]r
]z ]r ]r
1 ]
]F ]j
]F ]z ]z
1
rrvF 2 rGF (
1
)
r ]z
]j ]r
]z ]r ]r
]
]F ]j
]F ]z ]j
1
ruF 2 GF (
1
)
]j
]j ]z
]z ]z ]z
]
]F ]j
]F ]z ]z
1
ruF 2 GF (
1
)
5 SF
]z
]j ]z
]z ]z ]z
~
~
[14]
!
!
where
]j
1 ]z
5
,
]r
J ]z
]z
1 ]z ]j
1 ]r
52
,
52
,
]r
J ]j ]z
J ]z
1 ]r
]r ]z
]r
5
, J5
2
J ]j
]j ]z
]z
]z
]z
]z
]j
[15]
The transformation coefficients were calculated numerically, using the second-order central difference method. In
the transformed domain, the grid size was set to be unity
to simplify the calculation.
B. Technique of Solution
The calculation domain for u, v, and h excludes the solid
cathode. This is done by rendering the control volume of
Fig. 7Anode current density and heat flux for 200-A arc with 6.3-mm arc length (voltage 5 16.4 V).
the solid cathode inactive, so that the remaining active control volume forms the desired irregular domain
(BCDEFGB).
To solve the potential equation, the field is specified by
employing the true electrical conductivity of the solid cathode and the plasma fluid in their respective regions. Therefore, the problem is solved as a conduction problem
throughout the entire calculation domain.
The transformed Eq. [14] is discretized using the control
volume approach[14] in the transformed domain (Figure 3),
which results in an equation of the following form.
aPFP 5 aEFE 1 aWFW 1 aTFT 1 aBFB 1 S
[16]
F
L
i51 k51
m
i,k
2 Fm21
i,k
Fmax
, F,
F 5 0.01
[17]
IV.
Fig. 8Calculated current density for 200-A arc with 1-mm depression.
Fig. 11Anode current density and heat flux for a 200-A arc with 1-mm depression (voltage 5 16.4 V).
Fig. 12Anode current density and heat flux for a 200-A arc with 1.2-mm depression (voltage 5 17.6 V).
CONCLUSIONS
Bu
Cp
e
h
H
I
ja
jc
jz, jr
k
Kb
l
L, N
P
Pr
Q
Qc
Qc
Qioniz
Qr
r, u, z
r0
R
R1
R2
SR
T
u, v
Vc
VW
SYMBOLS
azimuthal magnetic field, Wb/m2
heat capacity, J/kg
electronic charge, C
plasma enthalpy, J/kg
height of welding arc, mm
arc current, A
anode current density, A/m2
cathode current density, A/m2
axial, radial current density, A/mm2
thermal conductivity, W/(m z K)
Boltzmans constant, J/K
arc length, m
total number of nodes in j and z directions of
grid
pressure, Pa
Prandtl number 5 Cpm/k
inflow rate of shielding gas, m3/s
convective contribution to anode heat flux,
W/m2
electron contribution to anode heat flux, W/m2
heat source from cathode fall to ionize plasma,
W/m2
radiative contribution to anode heat flux, W/m2
cylindrical coordinate system
radial coordinate of a point on base plate, m
radius of welding arc
cathode radius, m
internal radius of shielding nozzle, m
radiative heat loss term, W/m3
temperature, K
axial, radial velocities, m/s
cathode fall voltage, V
work function of anode material
Greek symbols
GF
general diffusion coefficient
error
l
parameter for calculating Qr, m
m
m0
j, z
r
s
f
F
viscosity, kg/(m z s)
permitivity of free space, H/m
transformed coordinate system
density, kg/m3
electrical conductivity, 1/(ohms z m)
potential, V
general dependent variable
Subscripts
a
ab
cal
exp
i, k
anode plate
anode boundary layer
calculated
experimental
j and z direction node numbers
REFERENCES
1. K.C. Hsu, K. Etemadi, and E. Pfender: J. Appl. Phys., 1983, vol. 54,
pp. 1293-1301.
2. R.T.C. Choo, J. Szekely, and R.C. Westhoff: Metall. Trans. B, 1992,
vol. 23B, pp. 357-69.
3. J.J. Lowke, P. Kovitya, and H.P. Schmidt: J. Phys. D: Appl. Phys.,
1992, vol. 25, pp. 1601-06.
4. J. Mckelliget and J. Szekely: Metall. Trans. A, 1986, vol. 17A, pp.
1139-48.
5. M.L. Lin and T.W. Eagar: Weld. J., 1985, vol. 64 (6), pp. 163s-169s.
6. R.T.C. Choo, J. Szekely, and R.C. Westhoff: Weld. J., 1990, vol. 69
(9), pp. 346s-361s.
7. M.L. Lin and T.W. Eagar: Metall. Trans. B, 1986, vol. 17B, pp. 60107.
8. S.Y. Lee and S.J. Na: Proc. Inst. Mech. Eng. Part B: J. Eng.
Manufacture, 1995, vol. 209, pp. 153-64.
9. C. Delalondre and O. Simonin: J. Phys. Coll., 1990, vol. 51, pp.
C5-C199.
10. P.Y. Zhu, J.J. Lowke, and R. Morrow: J. Phys. D: Appl. Phys., 1992,
vol. 25, pp. 1221-30.
11. H.G. Fan and Y.W. Shi: J. Mater. Processing Technol., 1996, vol.
61, pp. 302-08.
12. H.G. Fan, S.J. Na, and Y.W. Shi: J. Phys. D: Appl. Phys., 1997, vol.
30, pp. 1-9.
13. M.L. Lin and T.W. Eagar: Transport Phenomena in Materials
Processing, PED-Vol. 10, HTD-Vol. 29, ASME, New York, NY,
1983, pp. 63-69.
14. S.V. Patankar: Numerical Heat Transfer and Fluid Flow, Hemisphere,
Washington DC, 1980.
15. G.N. Haddad and A.J.D. Farmer: Weld. J., 1985, vol. 64 (12), pp.
339s-342s.
16. O.H. Nestor: J. Appl. Phys., 1992, vol. 33, pp. 1638-48.