The automotive industry corporations noticed the advantages of automated laser welding. Robot laser welding systems have immediately attracted their interests for bringing down the production costs and delivering higher-quality items. The objective of this research is to study how to enhance heat dissipation to endorse a better performance of the pressure wheel, and help achieve a longer life cycle. Transient thermal analysis of the pressure wheel was conducted using ANSYS workbench. The work studied the effects of different design models and materials on the thermal performance of pressure wheel assembly during the cooling period. Numerical simulations were performed on both solid and geometrically ventilated wheels for enhancing the heat dissipation performance of the wheel. Different materials were also be tested and compared. The analysis will support the design process by monitoring different parameters in terms of performance, heat loss and manufacturing cost.

A comparison was made for two different designs each with three different materials and the best design was selected. The simulation results in a period of 50 seconds cooling time showed that the temperature dropped with the 1st design (full solid wheel) made of tungsten from an initial temperature Ti = 500 K to a final temperature of Tf = 434.5 K. Tungsten was found to have better heat dissipation compared to stainless steel and cast iron. For the 2nd design (geometrically ventilated wheel) made of tungsten, the temperature drops from Ti = 500 K to Tf = 422.1 K. Comparing the two designs, the geometrically ventilated wheel was proved to be cooled faster. The present work will help improve the performance of pressure wheel in the welding industry by providing computational results for successive design testing and data validation.

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