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Prediction of angular distortion in the fiber laser keyhole welding process based on a variable-fidelity approximation modeling approach

Author

Listed:
  • Qi Zhou

    (Huazhong University of Science & Technology)

  • Longchao Cao

    (Huazhong University of Science & Technology
    Georgia Institute of Technology)

  • Hui Zhou

    (Nanyang Technological University)

  • Xiang Huang

    (Georgia Institute of Technology)

Abstract

The angular distortion is one of the most common types of distortions frequently observed in laser weld assembling processes, which leads to a decline in welding joints’ quality and additional costs of rework. Therefore, it is of great importance to control and reduce the welding-induced angular distortion by selecting appropriate welding process parameters. The challenge is how to predict the welding-induced angular distortion in the whole process parameter design domain accurately and efficiently. To address this challenge, a variable-fidelity approximation modeling approach is developed in this paper, where two different levels of fidelity data are integrated for predicting the angular distortion in the laser welding process. In the proposed approach, a three-dimensional thermo-mechanical finite element model is developed as a low-fidelity model, while the laser welding experiment is taken as a high-fidelity model. A low-fidelity radial basis function (RBF) model is constructed based on the sample data from the finite element simulation. Then a linear tuning strategy is introduced to bring the low-fidelity RBF model as close as possible to the data from the laser welding experiment. Finally, the variable-fidelity approximation model is constructed by adopting a scaling function to calibrate the remaining differences between the tuning low-fidelity approximation model and the high-fidelity data. Two types of validation approaches are adopted to compare the prediction accuracy of the variable-fidelity approximation model with those of the single-fidelity approximation models solely constructed with laser welding experiment or finite element simulation. Results illustrate that the prediction ability of the developed variable-fidelity approximation model outperforms those of the single-fidelity approximation models.

Suggested Citation

  • Qi Zhou & Longchao Cao & Hui Zhou & Xiang Huang, 2018. "Prediction of angular distortion in the fiber laser keyhole welding process based on a variable-fidelity approximation modeling approach," Journal of Intelligent Manufacturing, Springer, vol. 29(3), pages 719-736, March.
  • Handle: RePEc:spr:joinma:v:29:y:2018:i:3:d:10.1007_s10845-018-1391-1
    DOI: 10.1007/s10845-018-1391-1
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    Cited by:

    1. Cheng Yan & Jianfeng Zhu & Xiuli Shen & Jun Fan & Dong Mi & Zhengming Qian, 2020. "Ensemble of Regression-Type and Interpolation-Type Metamodels," Energies, MDPI, vol. 13(3), pages 1-20, February.
    2. Alejandro Alvarado-Iniesta & Luis Gonzalo Guillen-Anaya & Luis Alberto Rodríguez-Picón & Raul Ñeco-Caberta, 2020. "Multi-objective optimization of an engine mount design by means of memetic genetic programming and a local exploration approach," Journal of Intelligent Manufacturing, Springer, vol. 31(1), pages 19-32, January.
    3. Wu, Jianzhao & Zhang, Chaoyong & Giam, Amanda & Chia, Hou Yi & Cao, Huajun & Ge, Wenjun & Yan, Wentao, 2024. "Physics-assisted transfer learning metamodels to predict bead geometry and carbon emission in laser butt welding," Applied Energy, Elsevier, vol. 359(C).

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