管板电阻点焊熔核形成机理及特征分析方法研究
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摘要
近年来，随着人们对环境问题认识的不断深入和对安全性要求的不断提高，汽车车身构造和材料正在发生巨大变化。为了进一步实现车身轻量化和节能减排，液压成形管和高强钢等轻量化结构件与材料在车身中的应用日趋广泛。电阻点焊工艺由于其高效率、低成本的突出优点仍是现阶段连接液压成形管与高强钢材料的首选工艺方法，然而，在管板电阻点焊过程中，由于管件的刚度较小，焊接过程中会产生较大的焊接变形，易形成椭圆形熔核，变形严重时甚至出现裂纹等缺陷；同时，受高强钢自身材料性能的影响和零部件间搭接宽度的制约，传统高强钢焊点尺寸规范难以满足焊点接头强度要求，必须通过增加焊点数量来保证熔核质量，而椭圆形熔核通过控制熔核的长宽比，能在不增加焊点数量的前提下稳定高强钢点焊熔核质量。目前对椭圆形熔核的生成方法及其对焊点质量的影响仍未进行深入系统的研究，因此，本文针对椭圆形熔核的形成机理、焊接质量以及特征分析方法展开相关的研究工作，具有重要意义和研究价值。
基于上述研究背景和目标，本文首先建立用于获取椭圆形熔核的点焊试验系统，应用数值分析方法建立电阻点焊椭圆形熔核形成过程的三维有限元模型，揭示椭圆形熔核形成机理，并建立熔核长度与临界试样尺寸的logistic回归模型，为焊点间距的选取提供依据。通过拉剪测试的数值模拟和拉丁正交试验设计，建立椭圆形熔核几何尺寸、材料属性与拉剪强度的关系模型，实现对椭圆形熔核拉剪强度的定量预测。基于对高强钢板板点焊椭圆形熔核研究结果，进一步分析管板单面电阻点焊椭圆形熔核质量问题，研究工艺参数和结构尺寸对椭圆形熔核质量的影响规律，提出基于电极位移曲线的熔核生成过程和管体变形过程的有效分离方法，实现了管板点焊椭圆形熔核特征分析，为管板单面点焊焊接质量监控奠定基础。本文主要开展的研究工作如下：
1.点焊椭圆形熔核形成过程数值仿真建模与临界尺寸试验
为了获取不同尺寸的椭圆形熔核，分析熔核长度对高强钢点焊熔核拉剪强度和断裂失效模式的影响规律，本章首先建立用于获取点焊椭圆形熔核的试验系统，结合数值模拟研究椭圆形熔核形成过程机理，并验证电极端面尺寸与熔核形状的对应关系。然后通过拉剪测试试验研究和logistic回归分析方法，确定热镀锌双相钢DP600椭圆形焊点结构的临界试样宽度和临界试样厚度，以及它们与熔核长度、板材厚度的对应关系，并通过多点结构的拉剪测试进行验证。与圆形熔核相比，椭圆形熔核能够降低高强钢点焊结构发生分界面断裂失效的概率，增大焊点间距。
2.点焊椭圆形熔核拉剪强度预测方法
影响焊点拉剪强度的因素较多，不仅包括熔核几何尺寸，还包括焊件材料属性。为了分析焊点属性对椭圆形熔核拉剪强度的影响规律，本章建立了高强钢椭圆形焊点的拉剪测试数值仿真模型，确定了保证焊接质量的临界椭圆度，并结合拉丁正交试验设计方法，建立焊点几何参数和材料属性与拉剪强度的关系模型，实现对高强钢点焊椭圆形熔核拉剪强度的预测。
3.工艺和结构参数对管板点焊椭圆形熔核影响试验研究
由于车身结构零部件形状的复杂性，本章针对基于圆管的管板单面点焊连接方法展开研究。考虑管板的线接触状态和管材的对称性，设计开发了半圆形管材的加工模具以及相应的焊装夹具，建立管板单面点焊椭圆形熔核试验系统。由于管的内部缺乏有效支撑，在焊接过程中产生焊接变形，受结构形式非轴对称的影响，往往形成椭圆形环状熔核。本章首先通过金相试验和硬度分析，研究管板单面点焊的椭圆形熔核形态，以及焊接电流、焊接时间、电极力和电极错位等工艺规范对焊接变形和拉剪强度的影响。然后结合动态电阻分析，研究不同电极力、管材厚度和管材半径对管板单面点焊椭圆形熔核质量的影响规律。
4.基于电极位移的管板单面点焊椭圆形熔核特征分析
由于管板单面点焊特殊的结构形式，在电极力作用下发生焊接变形，而且容易出现虚焊、焊接飞溅或微裂纹等焊接缺陷，影响焊接质量。为了实现对管板单面点焊椭圆形熔核质量的特征分析，本章对总体电极位移曲线进行分解，建立管板单面点焊的三维有限元模型，确定焊接热量分配比例，分别获得相应的熔核生成过程和管体变形过程。通过对位移曲线分解结果的分析，可实现对虚焊、焊接飞溅和焊接微裂纹三种椭圆形熔核质量特征的分析。
通过以上研究，本文结合数值仿真、试验设计和统计分析等方法，确定了熔核长度与临界试样尺寸的关系模型，有效增大了焊点间距，降低了断裂失效模式的发生。建立了焊点属性与椭圆形熔核拉剪强度的关系模型，实现了椭圆形熔核拉剪强度的定量评价。并在此基础上确定了不同工艺参数和结构尺寸对管板单面点焊椭圆形熔核质量的影响规律，提出了基于电极位移曲线的熔核生成过程和管体变形过程的有效分离方法，实现了管板点焊椭圆形熔核特征分析，为高强钢管板单面点焊工艺分析、参数选取以及焊接质量在线监控奠定基础，研究成果具有较高的理论基础和实际应用价值。
During the last few years, with the developments of the recognition of environmentsand the requirements for the safety, the automotive body structure and materials arechanging greatly. For vehicle lightweight and energy saving, hydroforming technique andhigh strength steels (HSS) have been widely used in vehicle structure. Because of highefficiency and low costs, resistance spot welding is the mainly method for joining.However, in sheet to tube spot welding, welding deformation often occurs because of lowtube stiffness, and elliptical nugget is formed even with cracks. Moreover, because ofmaterial properties and limitation for purpose of minimizing the weld flange, welds mustbe increased to assure welding quality. Through controlling the aspect ratio, ellipticalnugget can stabilize welding quality without increasing welds, and research on theinfluence of elliptical nugget on welding quality is seldom addressed. Therefore, in thepresent paper, research works are conducted on nugget formation mechanism and weldingquality inspection method of elliptical nugget.
Based on the above backgrounds, experimental system of elliptical nugget isestablished firstly, and formation mechanism is studied by3D numerical simulation.Relationship between weld length and critical specimen size is determined combinedexperiments and logistic statistic analysis. Then relationships between weld attributes andwelding quality are established with numerical model of tensile-shear test and Latinhypercube design, and prediction of welding quality is achieved. Furthermore, ellipticalnugget size in sheet to tube spot welding is analyzed and influences of process andstructural parameters on welding quality are investigated. Last, decomposition of nuggetformation and tube deformation is proposed based on the electrode displacement, andcharacteristic of elliptical nugget can be analyzed, which provide reference for sheet totube spot welding quality control. Mainly research works are listed as follows
1. Numerical simulation and experimental study on critical size of elliptical nuggetin spot welding
In order to obtain elliptical nugget, experimental system of elliptical nugget isestablished, and formation mechanism is studied by simulation. Relationship betweenelectrode size and nugget shape is also verified. Combined experimental study and logisticanalysis, critical specimen sizes of DP600are determined and verified by multi-weldsstructure. Compared with circular nugget, elliptical nugget can minimize interfacialfracture and increase weld space.
2. Prediction of tensile-shear strength for elliptical nugget
There are many factors influenced tensile-shear strength, including nugget size andmaterial attributes. In order to analyze the effects of weld attributes on tensile strength,numerical model of tensile-shear test is established. The critical ellipticity is determinedand relationship between weld attributes and tensile strength is obtained. Last, ellipticalnugget size and influence of structural parameters on ellipticity are investigated further.
3. Influence of process and structural parameters on elliptical nugget in sheet totube spot welding
Sheet to cylindrical tube spot welding is investigated for complexity of vehiclecomponents. Manufacture dies and welding clamps are designed and experimental systemis established. Without support inside, welding deformation occurs and elliptical nugget isformed. The elliptical nugget is studied firstly by microstructure and hardness test.Influences of process parameters on welding deformation and tensile strength are alsoinvestigated. Then effects of electrode force, tube thickness and tube radius on ellipticalnugget welding quality are researched combined analysis of dynamic resistance.
4. Characteristic analysis of elliptical nugget in sheet to tube single sided spotwelding based on electrode displacement
Because of special structure, welding deformation happens in sheet to tube spotwelding, and cold weld, expulsion and crack often occur. In order to inspect weldingquality of elliptical nugget in sheet to tube spot welding, the electrode displacement isdecomposed, and nugget formation and tube deformation are obtained.3D finite elementmodel of sheet to tube spot welding is established and the proportion of welding energy isdetermined to get the course of nugget formation. Through analysis of electrodedecomposition, characteristic of welding defects in sheet to tube spot welding can be inspected.
Based on research above, combined numerical simulation, experimental design andstatistical analysis, relationship between nugget length and critical specimen size isdetermined, and weld space can be increased and interfacial fracture can be improved.Relationships between weld attributes and tensile strength are also established, and tensilestrength is evaluated. The influence of process and structural parameters on ellipticalnugget quality in sheet to tube spot welding is analyzed. And decomposition of nuggetformation and tube deformation is proposed based on the electrode displacement toanalyze elliptical nugget characteristic, which provide reference for process analysis,parameter selection and quality control. Research results have high theory foundation andapplication value.
基于上述研究背景和目标，本文首先建立用于获取椭圆形熔核的点焊试验系统，应用数值分析方法建立电阻点焊椭圆形熔核形成过程的三维有限元模型，揭示椭圆形熔核形成机理，并建立熔核长度与临界试样尺寸的logistic回归模型，为焊点间距的选取提供依据。通过拉剪测试的数值模拟和拉丁正交试验设计，建立椭圆形熔核几何尺寸、材料属性与拉剪强度的关系模型，实现对椭圆形熔核拉剪强度的定量预测。基于对高强钢板板点焊椭圆形熔核研究结果，进一步分析管板单面电阻点焊椭圆形熔核质量问题，研究工艺参数和结构尺寸对椭圆形熔核质量的影响规律，提出基于电极位移曲线的熔核生成过程和管体变形过程的有效分离方法，实现了管板点焊椭圆形熔核特征分析，为管板单面点焊焊接质量监控奠定基础。本文主要开展的研究工作如下：
1.点焊椭圆形熔核形成过程数值仿真建模与临界尺寸试验
为了获取不同尺寸的椭圆形熔核，分析熔核长度对高强钢点焊熔核拉剪强度和断裂失效模式的影响规律，本章首先建立用于获取点焊椭圆形熔核的试验系统，结合数值模拟研究椭圆形熔核形成过程机理，并验证电极端面尺寸与熔核形状的对应关系。然后通过拉剪测试试验研究和logistic回归分析方法，确定热镀锌双相钢DP600椭圆形焊点结构的临界试样宽度和临界试样厚度，以及它们与熔核长度、板材厚度的对应关系，并通过多点结构的拉剪测试进行验证。与圆形熔核相比，椭圆形熔核能够降低高强钢点焊结构发生分界面断裂失效的概率，增大焊点间距。
2.点焊椭圆形熔核拉剪强度预测方法
影响焊点拉剪强度的因素较多，不仅包括熔核几何尺寸，还包括焊件材料属性。为了分析焊点属性对椭圆形熔核拉剪强度的影响规律，本章建立了高强钢椭圆形焊点的拉剪测试数值仿真模型，确定了保证焊接质量的临界椭圆度，并结合拉丁正交试验设计方法，建立焊点几何参数和材料属性与拉剪强度的关系模型，实现对高强钢点焊椭圆形熔核拉剪强度的预测。
3.工艺和结构参数对管板点焊椭圆形熔核影响试验研究
由于车身结构零部件形状的复杂性，本章针对基于圆管的管板单面点焊连接方法展开研究。考虑管板的线接触状态和管材的对称性，设计开发了半圆形管材的加工模具以及相应的焊装夹具，建立管板单面点焊椭圆形熔核试验系统。由于管的内部缺乏有效支撑，在焊接过程中产生焊接变形，受结构形式非轴对称的影响，往往形成椭圆形环状熔核。本章首先通过金相试验和硬度分析，研究管板单面点焊的椭圆形熔核形态，以及焊接电流、焊接时间、电极力和电极错位等工艺规范对焊接变形和拉剪强度的影响。然后结合动态电阻分析，研究不同电极力、管材厚度和管材半径对管板单面点焊椭圆形熔核质量的影响规律。
4.基于电极位移的管板单面点焊椭圆形熔核特征分析
由于管板单面点焊特殊的结构形式，在电极力作用下发生焊接变形，而且容易出现虚焊、焊接飞溅或微裂纹等焊接缺陷，影响焊接质量。为了实现对管板单面点焊椭圆形熔核质量的特征分析，本章对总体电极位移曲线进行分解，建立管板单面点焊的三维有限元模型，确定焊接热量分配比例，分别获得相应的熔核生成过程和管体变形过程。通过对位移曲线分解结果的分析，可实现对虚焊、焊接飞溅和焊接微裂纹三种椭圆形熔核质量特征的分析。
通过以上研究，本文结合数值仿真、试验设计和统计分析等方法，确定了熔核长度与临界试样尺寸的关系模型，有效增大了焊点间距，降低了断裂失效模式的发生。建立了焊点属性与椭圆形熔核拉剪强度的关系模型，实现了椭圆形熔核拉剪强度的定量评价。并在此基础上确定了不同工艺参数和结构尺寸对管板单面点焊椭圆形熔核质量的影响规律，提出了基于电极位移曲线的熔核生成过程和管体变形过程的有效分离方法，实现了管板点焊椭圆形熔核特征分析，为高强钢管板单面点焊工艺分析、参数选取以及焊接质量在线监控奠定基础，研究成果具有较高的理论基础和实际应用价值。
During the last few years, with the developments of the recognition of environmentsand the requirements for the safety, the automotive body structure and materials arechanging greatly. For vehicle lightweight and energy saving, hydroforming technique andhigh strength steels (HSS) have been widely used in vehicle structure. Because of highefficiency and low costs, resistance spot welding is the mainly method for joining.However, in sheet to tube spot welding, welding deformation often occurs because of lowtube stiffness, and elliptical nugget is formed even with cracks. Moreover, because ofmaterial properties and limitation for purpose of minimizing the weld flange, welds mustbe increased to assure welding quality. Through controlling the aspect ratio, ellipticalnugget can stabilize welding quality without increasing welds, and research on theinfluence of elliptical nugget on welding quality is seldom addressed. Therefore, in thepresent paper, research works are conducted on nugget formation mechanism and weldingquality inspection method of elliptical nugget.
Based on the above backgrounds, experimental system of elliptical nugget isestablished firstly, and formation mechanism is studied by3D numerical simulation.Relationship between weld length and critical specimen size is determined combinedexperiments and logistic statistic analysis. Then relationships between weld attributes andwelding quality are established with numerical model of tensile-shear test and Latinhypercube design, and prediction of welding quality is achieved. Furthermore, ellipticalnugget size in sheet to tube spot welding is analyzed and influences of process andstructural parameters on welding quality are investigated. Last, decomposition of nuggetformation and tube deformation is proposed based on the electrode displacement, andcharacteristic of elliptical nugget can be analyzed, which provide reference for sheet totube spot welding quality control. Mainly research works are listed as follows
1. Numerical simulation and experimental study on critical size of elliptical nuggetin spot welding
In order to obtain elliptical nugget, experimental system of elliptical nugget isestablished, and formation mechanism is studied by simulation. Relationship betweenelectrode size and nugget shape is also verified. Combined experimental study and logisticanalysis, critical specimen sizes of DP600are determined and verified by multi-weldsstructure. Compared with circular nugget, elliptical nugget can minimize interfacialfracture and increase weld space.
2. Prediction of tensile-shear strength for elliptical nugget
There are many factors influenced tensile-shear strength, including nugget size andmaterial attributes. In order to analyze the effects of weld attributes on tensile strength,numerical model of tensile-shear test is established. The critical ellipticity is determinedand relationship between weld attributes and tensile strength is obtained. Last, ellipticalnugget size and influence of structural parameters on ellipticity are investigated further.
3. Influence of process and structural parameters on elliptical nugget in sheet totube spot welding
Sheet to cylindrical tube spot welding is investigated for complexity of vehiclecomponents. Manufacture dies and welding clamps are designed and experimental systemis established. Without support inside, welding deformation occurs and elliptical nugget isformed. The elliptical nugget is studied firstly by microstructure and hardness test.Influences of process parameters on welding deformation and tensile strength are alsoinvestigated. Then effects of electrode force, tube thickness and tube radius on ellipticalnugget welding quality are researched combined analysis of dynamic resistance.
4. Characteristic analysis of elliptical nugget in sheet to tube single sided spotwelding based on electrode displacement
Because of special structure, welding deformation happens in sheet to tube spotwelding, and cold weld, expulsion and crack often occur. In order to inspect weldingquality of elliptical nugget in sheet to tube spot welding, the electrode displacement isdecomposed, and nugget formation and tube deformation are obtained.3D finite elementmodel of sheet to tube spot welding is established and the proportion of welding energy isdetermined to get the course of nugget formation. Through analysis of electrodedecomposition, characteristic of welding defects in sheet to tube spot welding can be inspected.
Based on research above, combined numerical simulation, experimental design andstatistical analysis, relationship between nugget length and critical specimen size isdetermined, and weld space can be increased and interfacial fracture can be improved.Relationships between weld attributes and tensile strength are also established, and tensilestrength is evaluated. The influence of process and structural parameters on ellipticalnugget quality in sheet to tube spot welding is analyzed. And decomposition of nuggetformation and tube deformation is proposed based on the electrode displacement toanalyze elliptical nugget characteristic, which provide reference for process analysis,parameter selection and quality control. Research results have high theory foundation andapplication value.
引文
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