Oscillating Laser Welding Heat Source Modeling With Equivalent Gaussian Fits
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heat source models for oscillating laser welding are inefficient and inaccurate due to the complexity introduced by the oscillating laser beam, leading to prolonged calibration cycles and reduced simulation accuracy.
Innovation Solution
An equivalent heat source modeling method that constructs Gaussian heat source models by extracting energy distribution curves and spatial position information from an energy distribution cloud chart, verifying their matching degrees with actual laser welding sources, and using these models for simulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing heat source models are used for oscillating laser welding simulation, then the model can be applied to the welding process, but the calculation time is greatly prolonged and simulation efficiency is compromised
Solution Approach 1:
The patent segments the oscillating laser beam's continuous energy distribution into multiple discrete Gaussian heat source elements. Each Gaussian element represents a portion of the total energy distribution at different oscillation positions, allowing the complex oscillating heat source to be modeled as a superposition of simpler Gaussian components. This segmentation enables more efficient calculation while maintaining accuracy.
Solution Approach 2:
The patent transforms the heat source model parameters by introducing time-dependent oscillation parameters (amplitude, frequency, trajectory) into the Gaussian heat source equations. Instead of using a static heat source model, the parameters are dynamically adjusted to reflect the oscillating laser beam's position and energy distribution at each moment, enabling accurate simulation without prolonged calculation time.
2Measurement precision
If correction parameters are added to heat source models to improve precision, then the model accuracy improves, but the model complexity increases and is not suitable for oscillating laser welding
Solution Approach 1:
The patent makes the heat source model dynamic by incorporating the oscillating laser beam's motion characteristics. The Gaussian heat source parameters (position, intensity distribution) are updated dynamically according to the oscillation trajectory, amplitude, and frequency. This dynamic approach accurately captures the time-varying nature of oscillating laser welding without requiring complex correction parameters.
Solution Approach 2:
The patent creates a simplified copy of the actual oscillating heat source using Gaussian distribution functions. Instead of directly modeling the complex physical oscillating beam with all its nuances, the Gaussian heat source serves as an equivalent mathematical representation that captures the essential energy distribution characteristics, reducing model complexity while maintaining accuracy.
3Adaptability or versatility
If an oscillating trajectory is added to the heat source model, then the model better represents the actual process, but the simulation process becomes more complex and calibration accuracy is compromised
Solution Approach 1:
The oscillating trajectory is segmented into discrete position points corresponding to different phases of oscillation. At each position point, a Gaussian heat source is calculated based on the laser beam's instantaneous location and energy distribution. This segmentation of the continuous oscillation path into discrete Gaussian elements simplifies the overall simulation process while accurately representing the oscillating trajectory.
Solution Approach 2:
The patent merges multiple Gaussian heat sources at different oscillation positions into a single equivalent heat source model. By superimposing the energy distributions of individual Gaussian elements along the oscillation trajectory, the model captures the overall effect of the oscillating beam without requiring separate calculations for each trajectory point, reducing simulation complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies the calculation process and improves simulation efficiency by constructing high-precision equivalent Gaussian heat source models without repeated parameter adjustments, significantly shortening calibration cycles.
Implementation Method 1
allows a laser beam to oscillate though the galvanometric technique to change energy distribution of a heat source
Implementation Method 2
Constructing a corresponding equivalent Gaussian heat source model for each of the target points of interest according to the spatial position information of the target points of interest and features of the energy distribution curve
Data Source
AI summary
The invention discloses an equivalent heat source modeling method for oscillating laser welding, comprising: constructing an energy distribution cloud chart of an actual laser welding heat source under different oscillating trajectories, oscillating frequencies and oscillating amplitudes; extracting an energy distribution curve along the center of the heat source, and acquiring spatial position information of multiple target points of interest; constructing an equivalent Gaussian heat source model for each of the target points of interest; and verifying matching degrees between each Gaussian heat source model and the actual laser welding heat source, and taking Gaussian heat source models passing the verification as equivalent heat source models of the actual laser welding heat source. The invention also provides a simulation method for oscillating laser welding, which constructs an equivalent heat source model through the equivalent heat source modeling method, and perform welding simulation based on the equivalent heat source model.