# Development of a Virtual Reality-Based System for Simulating Welding Processes
###### Abstract  
Arc welding processes, such as shielded metal arc welding (SMAW), metal inert gas (MIG), and tungsten inert gas (TIG), play an important role in industrial applications. To improve the efficiency of the exploitation of traditional welding systems, new technologies have been used. Virtual reality technology is one of them. The virtual reality (VR)-based welding system enables to increase the frequency of practice to help learners obtain welding experience to avoid errors that occur during actual welding processes. This paper presents a VR-based system for simulating three welding processes: SMAW, MIG, and TIG. The developed system includes hardware components and VR software installed on a computer. The change in the physical devices, such as moving the welding torch and the distance from the welding torch to the plates to generate the weld bead, will update in real time and appear on the virtual environment. The functionality of the developed system for simulating the welding processes, such as in the real welding environment, was tested successfully. For implementing the system, welding speed and the distance from the welding torch to the plates are important process parameters, which determine the weld size or the weld formation. In this research, the ranges of the welding speed are \(70\div 120\) mm/min; \(240\div 460\) mm/min; and \(250\div 450\) mm/min for the SMAW, TIG, and MIG processes, respectively. These values were tested experimentally. The distance from the welding torch to the plates to display the weld joint is \(1.5\div 5\) mm. Outside of this range, no weld joint is formed. The welding widths are \(4.4\div 12.9\) mm, \(7.1\div 12.4\) mm, and \(7.4\div 11.3\) mm for the SMAW, TIG, and MIG processes, respectively. virtual reality; welding process; simulation; shielded metal arc welding; metal inert gas; tungsten inert gas +
Footnote †: journal: Applied  
Acticle Development of a Virtual Reality-Based System for Simulating Welding Processes  
[PERSON], [PERSON]; [PERSON] Development of a Virtual Reality-Based System for Simulating Welding Processes  
Applid  
3136082023133008202  
visualization in three dimensions (3D) and the processing of user interactions in real time are mandatory for the VR systems [7; 8; 9]. With the goal of helping learners understand the welding mechanisms as well as knowing the errors that will lead to poor welding quality and to minimize errors before practicing on real welding machines, from the literature review, many welding simulation systems have been developed. For simulating the SMAW welding process, [PERSON] developed a virtual welding system using ultrasound, infrared, optical rotary encoder, linear variable differential transformer (LVDT), and inertial measurement unit (IMU) sensors. The VR system consists of helmet, touch screen, welding gun, coupons, computer, and converters considered as hardware, and the simulation environment consists of software [1]. [PERSON] et al. also developed a simulator of an SMAW welding process with haptic display in which the virtual electrode providing the haptic sense is realized by the electromagnetic. The electrode position is measured by the image-based registration [10]. For simulating the MIG welding process, the VR-based MIG systems were proposed [11; 12; 13; 14; 15]. These systems include hardware components, such as helmet, welding torch, workpiece, computer, head-mounted display, tracking system for both the welding torch and the user's head, and external audio speakers. The track model of the welding simulator uses single-camera vision measurement technology to calculate the position of the welding torch and helmet. The simulation model uses a simple model method to simulate the weld geometry based on the orientation and speed of the welding torch. [PERSON] et al. introduced the commercial VRTEX 360 system by Lincoln Electric. This system is helpful for training welding skills before carrying out real welding [16]. [PERSON] et al.