Simulation And Optimiztion On Welding Deformation Of Big Size Hopper

In the industrial processes of manufacturing and assembling,metal welding is often carried out.Hence,the distortion in the output product is inevitable.These distortions are formed as a result of the high temperature transformations during the welding process.Therefore,our main aim is to reduce deformations in the hopper caused by welding by using experimental methods and Finite Element Analysis(FEA)including inherent strain method.Hoppers are structures used in many industries to facilitate bulk material transfer from one conveyer belt to the other,or for redirecting flow from a delivery point.Through our research,we found that hopper must be designed and manufactured with high standards to reduce the distortion of metal during the welding process.This paper focuses on how to control welding deformation by using a variety of methods.Deformation occurs because the fast heating and cooling "thermal cycling" have an effect on its mechanical properties after it gets hardened.We have analyzed ways to control the welding deformation by using Finite Element Analysis(FEA).In addition,we have done further study to solve the issue by adding U shape and V shape including the bevel angle on edges of hopper.The results obtained are promising and have shown that the maximum deformations are reduced to meet ISO standard.Study thin plate deformation properties and residual stresses calculations among the effect of welding distortion of the hopper.To ensure our study and methods have reduced the amount of distortion of hopper,we have done experimental analysis to compare our results with finite element method(FEA)of our study with previous ones.Consequently,the investigation of welding parameter and boundary condition of welding process have been calculated and the result of experiments on hopper shows that the maximum welding deformation of hopper is similar to the result of analysis by finite element method(FEA).This paper develops the structure of hopper by using new design as U shape and V shape to absorb the deformation as heat distribution will mainly affect the surrounding of U or V shape.Therefore,to study the development of welding methods such as speed,voltage,and current that will affect the welding deformation.However,the optimization of bevel angle also can predict welding deformation.The final results and values of optimization shown on analysis tools have minimized the welding distortions.Consequently,we have used U and V shape optimization and bevel angle including welding methods.We have reached our aim of this thesis to reduce welding distortion of hopper structure and meet ISO standard.