Research on Predicting Welding Deformation in Automated Laser Welding Processes with an Enhanced DEWOA-BP Algorithm

Welding stands as a critical focus for the intelligent and digital transformation of the machinery industry, with automated laser welding playing a pivotal role in the sector’s technological advancement. The management of welding deformation in such operations is fundamental, relying on advanced analysis and prediction methods. The endeavor to accurately analyze welding deformation in practical applications is compounded by the interplay of numerous variables, a pronounced coupling effect among these factors, and a reliance on expert intuition. Thus, effective deformation control in automated laser welding operations necessitates the gathering of pre-test laser welding data to develop a predictive approach that accurately reflects real-world conditions and is characterized by improved reliability and stability. To address the technological evolution in automated laser welding, a predictive model based on neural network technology is proposed to map the intricate relationship between process variables and the resulting deformation. At the heart of this approach is the formulation of a predictive model utilizing a back-propagation neural network (BP), with an emphasis on four essential welding parameters: speed, peak power, duty cycle, and defocusing amount. The model’s predictive accuracy is then honed through the application of the whale optimization algorithm (WOA) and the differential evolutionary (DE) algorithm. Finally, extensive testing in an automated laser welding experimental setup is conducted to validate the accuracy and reliability of the proposed prediction model. It is demonstrated through these experiments that the deformation prediction model, enhanced by the DEWOA-BP neural network, accurately forecasts the relationship between laser welding parameters and the induced deformation, maintaining a prediction error margin of ±0.1mm. The model is employed to fulfill the requirements for a pre-welding quality evaluation, thereby facilitating a more calculated and informed approach to welding operations. This method of intelligent prediction is not only crucial for the intelligent transformation of laser welding but also holds significant implications for traditional machining technologies such as milling, grinding, and spraying. It offers innovative ideas and methods that are pivotal for the industrial revolution and technological advancement of the traditional machining industry.