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<p>This paper develops an improved simulation model for the gas metal arc welding process, incorporating the arc root conduction zone, the transistorized power supply, and its PID-controller parameters. The model is applicable to short-circuiting, free-flight, and active control transfer modes. For the short-circuiting transfer mode, the molten metal bridging electrode tip and workpiece is modelled with a parabolic wall profile, dependent on its height. This approach significantly simplifies and accurately addresses numerical issues and singularities in calculating the principal radii. Furthermore, the pressure due to the electromagnetic force is determined, and the average velocity of the transferred liquid metal is estimated using Bernoulli’s equation. In the free-flight transfer mode, based on the dynamic force balance model, the arc root zone is considered thanks to the relationship between the arc current and the current emission density. Finally, the proposed model is simulated using MATLAB/SIMULINK, and the simulation results are discussed and compared with those in the specialized literature, showing a great accordance.</p>

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Improved GMAW process simulation modelling by considering arc root conduction zone and transistorized power source

  • 期刊论文

  • 发表日期：

    2025年1月15日

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  • Saad Chaouch,
  • Sayah Merazi,
  • Hani Terfa,
  • Leila Belgacem,
  • Hasni Mourad

摘要

This paper develops an improved simulation model for the gas metal arc welding process, incorporating the arc root conduction zone, the transistorized power supply, and its PID-controller parameters. The model is applicable to short-circuiting, free-flight, and active control transfer modes. For the short-circuiting transfer mode, the molten metal bridging electrode tip and workpiece is modelled with a parabolic wall profile, dependent on its height. This approach significantly simplifies and accurately addresses numerical issues and singularities in calculating the principal radii. Furthermore, the pressure due to the electromagnetic force is determined, and the average velocity of the transferred liquid metal is estimated using Bernoulli’s equation. In the free-flight transfer mode, based on the dynamic force balance model, the arc root zone is considered thanks to the relationship between the arc current and the current emission density. Finally, the proposed model is simulated using MATLAB/SIMULINK, and the simulation results are discussed and compared with those in the specialized literature, showing a great accordance.