The Dynamic Simulation And Verification Of The Tandem Pulsed MIG Welding

As a welding method of high efficiency and low energy consumption, double arc welding has a favorable foreground in the practical production. This paper brings forward a new method of high efficiency --Tandem pulsed MIG welding on the basis of the development trends of double arc welding. Since there are a large amount of adjustable parameters, a large number of repeated experiments are required to determine the optimal welding parameters, which will cause a great consumption of materials, energy and manpower. Therefore, it is necessary to design a more practical and reasonable simulation model to raise prediction accuracy of welding process parameters and to obtain the optimum welding technology properties.After the study of the mechanism of tandem pulsed MIG welding process and the simulating research achievements of other welding methods, dynamic simulations were performed on the systems of constant wire-feeding tandem pulsed MIG welding process with the MATLAB/SIMULINK. The simulation model of the two systems was developed, which consists of the main circuit simulation model, arc load system and arc changing system simulation model respectively. It also analyzed the influence of the simulation parameters (pulsed frequency/assumed peak voltage/assumed base voltage) and the wire feeding speed on the simulation waveform. The simulation results proved that the influence of the above parameters is remarkable. It is feasible to control the arc voltage and welding current in a certain range through adjusting the pulsed parameters and the wire feeding speed of the simulation model for tandem pulsed MIG welding.After using the parameters determined by the simulation to do practical experiments, good agreement is achieved between the simulation and experimental results, thus the rationality of the simulation system is proved. In addition, the results of the arc behavior received from the high-speed camera technique have proved the rationality of the simulation system furthermore.Therefore the designed simulation system plays an important role in predicting welding process parameters, shortening the experiment period and saving the consumption of materials, energy and manpower greatly.