Laser Welding Simulation

Simulation of keyhole formation and molten pool flow in laser welding. Physical models for evaporation, plume formation, and multiple reflections due to high power density. Prediction of bead shape and spatter generation.

Expressing this with equations, it looks like this.

Evaporation recoil pressure inside the keyhole:

Laser welding simulation is formulated as a coupled problem of thermodynamics, material mechanics, and fluid dynamics. Since the physical phenomena of manufacturing processes span multiple time and spatial scales, an appropriate combination of macro-scale continuum models and meso/micro-scale material models is required. The goal is to quantitatively predict the causal relationship between process parameters (temperature, speed, load, etc.) and product quality (dimensional accuracy, defects, mechanical properties).

The accuracy of manufacturing process simulation heavily depends on the fidelity of the material model. It is necessary to properly define elastoplastic constitutive laws, creep laws, phase transformation models, etc., as functions of temperature and strain rate. Data obtained from material testing (tensile, compression, torsion) is fitted, and validity in extrapolation ranges is verified. Thermodynamic databases like JMatPro and Thermo-Calc are also utilized.

Manufacturing process simulation is formulated as a coupled problem of thermodynamics, fluid dynamics, and solid mechanics.

Here, $T$ is temperature, $\mathbf{v}$ is the material velocity field, $k$ is thermal conductivity, and $Q$ is internal heat generation (Joule heat, latent heat, frictional heat, etc.).

During solidification, the release/absorption of latent heat significantly affects the temperature field. Formulation using the enthalpy method:

Expressing this with equations, it looks like this.

Here, $L$ is the latent heat, and $f_l(T)$ is the liquid fraction (taking a value between 0 and 1 in the solid-liquid coexistence region).

Plastic deformation of metals is described by constitutive laws such as Johnson-Cook:

$A$: Initial yield stress, $B$: Hardening coefficient, $n$: Hardening exponent, $C$: Strain rate sensitivity, $m$: Thermal softening exponent.

The flow of molten metal or resin follows the Navier-Stokes equations, but high viscosity and non-Newtonian fluid characteristics must be considered. For injection molding, the Cross-WLF model is standard: