An effective and rigorous approach to determine optimum welding process parameters is implementation of advanced computer aided engineering (CAE) tool that integrates efficient optimization techniques and numerical welding simulation. In this paper, an automated computational methodology to determine optimum arc welding process control parameters is proposed. It is a coupled Genetic Algorithms (GA) and Finite Element (FE) based optimization method where GA directly utilizes output responses of FE based welding simulations for iterative optimization. Effectiveness of the method has been demonstrated by predicting optimum parameters of a lap joint specimen of two thin steel plates for minimum distortion. Three dimensional FE model has been developed to simulate the arc welding process and validated by experimental results. Subsequently, it is used by GA as the evaluation model for optimization. The optimization results show that such a CAE based method can predict optimum parameters successfully with limited effort and cost.

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