Virtual Manual Arc Welding by Real-Time Process Simulation for an Effective Training

Document Type : Research Article


1 Mechanical Engineering Department, Amirkabir University of Technology

2 New Technologies Research Center, Amirkabir University of Technology, Iran

3 Mechanical Engineering Department, Khajenasir Toosi University of Technology


Training is usually carried out throughout traditional methods which impose enormous costs. Virtual reality is one of the most suitable methods that has been presented in this application and improves many of the weak points of traditional training such as high cost of welding. Previous studies were conducted on virtual welding with the use of virtual reality techniques in welding training. The novelty of this article is that uses Kinect for tracking and Adaptive meshing for thermal analysis. The dimension of workpiece is 70x50x10 and the material is low carbon steel. The user performs real-time welding in the virtual environment by moving the electrode clamp. Since process parameters like current, hand motion speed, arc length, and welding voltage make changes in generated heat, and color of molten-solid zone, a graphic interface updates the color in each part of the model. The process is modeled in two different ways of fixed and adaptive mesh finite element approaches which manifests good precision and calculation of speed, respectively. All calculations in the simulation environment and the thermal analysis engine performed in the C# program. One of the positive features of the simulator is self-learning. A novice welder could take enough time to learn the manual arc welding simulator without any extra cost or danger. This simulator provides a good training ability to control the welding parameters.


Main Subjects

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