Modeling and analysis of simultaneous laser transmission welding of polycarbonates using an FEM and RSM combined approach

In this paper, simultaneous laser transmission welding process is systematically investigated via process modeling, using an FEM and RSM combined approach. The objective of the present research is to study the effects of process parameters on the temperature field and weld bead dimensions. The thermal field is simulated by solving a three dimensional transient heat diffusion equation with temperature dependent material properties using the ANSYS ® multi-physics. Response surface methodology is then applied for developing mathematical models based on simulation results. The second order equations developed by RSM can predict the values of the responses with significant accuracy. The effect of parameters and their interactions on the responses are studied using the developed response surface models. The mathematical models are further used in search of the optimal process window for obtaining an acceptable weld. The graphical optimization results into a couple of overlay contours plots, which allow quick visual inspection of the area of feasible response values in the factor space to choose the favorable welding parameter combination. ►FEM along with RSM is employed to study the simultaneous laser transmission welding process. ► The numerical simulation is performed using the commercial FE package ANSYS ®. ► The temperature distribution and shape and size of the molten pool are computed. ► RSM is used to analyze the responses and to determine the mathematical models with best fits. ► The effect of parameters and their interactions on the responses are studied and discussed.