激光电弧复合焊接数值模拟
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摘要
焊接是一个涉及物理、传热、冶金和力学等学科的复杂过程。高强钢由于其良好的性能在造船等重型机械中得到广泛应用,但正因为其用途的特殊性,对其连接技术也提出了更高的要求。
本文以7mm厚的高强钢为研究对象,结合数值计算的方法,并利用有限元分析理论,选用高斯分布的热源模型,解决了热源移动的模拟。通过确定物理参数的变化,解决相变潜热等问题。利用ANSYS模拟了整个焊接过程的温度场分布,模拟对比了不同激光功率、电弧电流、焊接速度下的的温度场分布,得到了相应的熔深和熔宽的大小,并通过试验一一进行验证,模拟结果和试验测得的数据吻合良好。
试验证明:复合焊接能实现良好的桥接性,焊缝硬度高于母材,但低于单独的激光焊接,焊缝均匀性好。电弧的引入明显增加了焊接的熔深和熔宽。随着激光功率的增大,熔深增大,但超过一定值反而下降。电弧电流、焊接速度、激光离焦量、激光与电弧的距离都对焊缝的成型有重要影响,当这些参数达到合理的配置时,焊接质量最好。在激光功率2kw,相应电弧电流100A左右,焊接速度1m/min时,焊缝形貌美观,熔深大。在离焦量为-1mm,激光与电弧距离为2mm的条件下,熔池稳定,焊接效果好。
Welding is a complex processing which involve physics, heat transforming, metallurgy and mechanics and so on subjects. High-strength steel has wonderful performance, so it is used in the ship building and the heavy mechanical industry. As the particularity purpose of the High-strength steel, the higher welding technology is needed.
The research object in this paper is the 7mm thick High-strength steel. Based on the finite element analysis theory, numerical calculation, choosing the gauss distributing heat fountain model, the simulation of heat fountain floating has been done. The change of physics parameter is confirmed, and then the hidden heat of the phase changing is solved. Used the ANSYS, the temperature distributing picture has been simulated in the whole welding process. The different laser power, electricity arc, and welding velocity have been compared in the simulation. And the different temperature field distributing, relevant melt depth and the melt width have been gotten. Then the welding practical test has been done, the result match perfectly.
The test validate that the hybrid welding have good bridge performance, the welding line rigidity is higher then the mother material, but it is lower then the laser welding, the equality of the weld line is well. The electricity arcs increase the welding melt depth and the width obviously. Along with the higher laser power, the melt depth is increased, but when the laser power is increased a certain value, the melt depth is declined. The electricity arc, welding velocity, laser defocus, and the distance between laser and electricity arc are important to the welding line modeling. When these parameters are configured reasonably, the quality of the welding is excellent. When the laser power equals to 2 kw, the relevant arc electricity equals to 100A, the welding velocity equals to 1m/min, the welding line looks beauty, the melt depth is bigger. When the defocus equals to -1mm, the distance between the laser and the arc equals to 2mm, the melt pool is stabile and the welding results is wonderful.
本文以7mm厚的高强钢为研究对象,结合数值计算的方法,并利用有限元分析理论,选用高斯分布的热源模型,解决了热源移动的模拟。通过确定物理参数的变化,解决相变潜热等问题。利用ANSYS模拟了整个焊接过程的温度场分布,模拟对比了不同激光功率、电弧电流、焊接速度下的的温度场分布,得到了相应的熔深和熔宽的大小,并通过试验一一进行验证,模拟结果和试验测得的数据吻合良好。
试验证明:复合焊接能实现良好的桥接性,焊缝硬度高于母材,但低于单独的激光焊接,焊缝均匀性好。电弧的引入明显增加了焊接的熔深和熔宽。随着激光功率的增大,熔深增大,但超过一定值反而下降。电弧电流、焊接速度、激光离焦量、激光与电弧的距离都对焊缝的成型有重要影响,当这些参数达到合理的配置时,焊接质量最好。在激光功率2kw,相应电弧电流100A左右,焊接速度1m/min时,焊缝形貌美观,熔深大。在离焦量为-1mm,激光与电弧距离为2mm的条件下,熔池稳定,焊接效果好。
Welding is a complex processing which involve physics, heat transforming, metallurgy and mechanics and so on subjects. High-strength steel has wonderful performance, so it is used in the ship building and the heavy mechanical industry. As the particularity purpose of the High-strength steel, the higher welding technology is needed.
The research object in this paper is the 7mm thick High-strength steel. Based on the finite element analysis theory, numerical calculation, choosing the gauss distributing heat fountain model, the simulation of heat fountain floating has been done. The change of physics parameter is confirmed, and then the hidden heat of the phase changing is solved. Used the ANSYS, the temperature distributing picture has been simulated in the whole welding process. The different laser power, electricity arc, and welding velocity have been compared in the simulation. And the different temperature field distributing, relevant melt depth and the melt width have been gotten. Then the welding practical test has been done, the result match perfectly.
The test validate that the hybrid welding have good bridge performance, the welding line rigidity is higher then the mother material, but it is lower then the laser welding, the equality of the weld line is well. The electricity arcs increase the welding melt depth and the width obviously. Along with the higher laser power, the melt depth is increased, but when the laser power is increased a certain value, the melt depth is declined. The electricity arc, welding velocity, laser defocus, and the distance between laser and electricity arc are important to the welding line modeling. When these parameters are configured reasonably, the quality of the welding is excellent. When the laser power equals to 2 kw, the relevant arc electricity equals to 100A, the welding velocity equals to 1m/min, the welding line looks beauty, the melt depth is bigger. When the defocus equals to -1mm, the distance between the laser and the arc equals to 2mm, the melt pool is stabile and the welding results is wonderful.
引文
[1]吴圣川 刘建华 铝合金激光-电弧复合焊的有限元数值模拟 航空制造技术2005年12期74-76
[2]卢振洋 等基于ANSYS薄板GTAW焊接温度场数值模拟 微计算机信息2007年23卷21期291-292
[3]陈彦斌,徐庆鸿,苏彦东.激光-同轴电弧复合焊接热源焊接[J]焊接学报,1995 16(4):239-243
[4]刘黎明等 镁合金激光-TIG复合热源焊接热源模型的建立及其数值模拟机械工程学报2006年2月82-86
[5]张旭东等CO_2激光-MIG同轴复合焊方法及铝合金焊接的研究应用激光2005年2月1-3
[6]武传松.焊接热过程数值分析.哈尔滨:哈尔滨工业大学出版社,1990
[7]陈楚等.数值分析在焊接中的应用.上海:上海交通大学出版社,1985,1.80-82
[8]林得超.焊接过程应力应变特征及其控制的数值模拟.博士学位论文.西安交通大学 博士学位论文,1997
[9]樊丁.YAG激光与脉冲MIG复合[j].焊接学报,2002 23(5):160-166.
[10]潘际孪.二十一世纪焊接科学研究的展望.第九次全国焊接会议论文集.哈尔滨:黑龙江人民出版社,1999:D1-D17
[11]熊蜡森.焊接工程基础.第一版.北京:机械工业出版社,2002
[12]黄旺福,黄金刚.铝及铝合金焊接指南.第一版.湖南:湖南科学技术出版社,2004
[13]左铁川.高强铝合金的激光加工.第一版.北京:国防工业出版社,2002
[14]熊建钢 深熔激光焊接小孔和熔池形状数学模型及工艺参数ANN优化设计.[博士学位论文]。武汉:华中科技大学,2001
[15]张屹.激光深熔焊接小孔效应的理论和试验研究:[硕士学位论文].湖南:湖南大学,2002
[16]Remy Fabbro,Karim Chouf.Dynamical description of the keyhole in deep penetration laser welding.JOURNAL OF LASRE APPLICATIONS,2000 Vol(4):142-147
[17]T.Graf,H.Staufer.Laser-hybrid welding.Welding Journal,2003(1):42-48
[18]王威,李丽群,忘旭友等.激光电弧复合焊接技术.焊接,2004(3):6-9
[19]张志勇,田志凌,彭云.铝合金先进焊接工艺.焊接,2003(7):5-9
[20]曹丽杰.铝合金的激光焊接:[硕士学位论文]。哈尔滨工业大学,2001
[21]T.GRF,H.STAUFER.Laser Hybrid Welding Drivers VW Improvements.Welding Journal,2004,Vol(83):43-47
[22]T.Graf,H.Staufer.Laser-hybrid welding.Welding Journal,2003(1):42-48
[23]陈彦宾.激光-TIG复合热源焊接物理特性研究:[博士学位论文]。哈尔滨:哈尔滨工业大学,2003
[24]S.Kaierle,K.Bongard,M.Dahmen,R.Poprawe.Innovative Hybrid Welding Process in an Industrial Application.Section C-ICALEO:2000.91-98.
[25]张旭东,陈武柱.激光电弧同轴复合焊矩[z]中国:CN144661A,2003.
[26]STAUFER HERBERT.Laser-Hybrid Welding of Ships.Welding Journal,2004 Vol(83)39-43
[27]Matsuda J,Utsumi A,et al.TIG or MIG arc augmented laser welding of thick mild steel plate.Joining &Materials, 1988,1(1):31-34
[28]Jasnau Ulf,Hoffmann Jan,Seyffarth Peter.Nd:YAG-lascr-gas metal arc-hybrid welding:a chance for the use of the advantages of laser technology and flexible automation in shipbuilding and steel construction[R].RWIA,2002,
[29]GrafT,Staufer H.Laser-hybrid welding drives VW improvements[J].Welding Journal,2003,82(I):42-48
[30]Kairle S,bongard K,dahmen M,et al.Innovative Hybrid Welding Process in an Industrial Application[A].Procedings of the Laser Materials Processing Conference[C].Section C-ICALEO,2000:91-98.
[31]陈伯蠡.焊接冶金原理.第一版.北京:清华大学出版社,1991
[32]陈楚,汪建华,杨洪庆.非线性焊接热传导的有限元分析和计算.焊接学报,1983(3):139-148
[33]陈楚,汪建华,杨洪庆.水下焊接冷却特性的有限元分析.海洋工程,1983(4):34-38
[34]鹿安理,史清宇,赵海燕等.厚板焊接过程温度场、应力场的三维有限元数值模拟.中国机械工程,2001.12(2):183-186
[35]Y.Ueda.Analysis of thermal elastic-plastic stress and strain during welding.Trans.Japan Welding,1971,2(2):90-100
[36]J.Goldak.Thermal Stress Analysis of Welds.From melting point to room temperature.Pro.Theoretical Prediction in Joining and Welding(Osaka,Japan),1996:225-230
[37]蔡洪能 唐慕尧.TIG焊接温度场的有限元分析,机械工程学报,1996.32(2):34-39
[38]Paley Z,Hibbert P D.Computation of Temperation in Actual Weld Designs.Welding Journal 1975,54(11):385-392;
[39]吕高尚 董春林 激光电弧复合热源焊接研究及应用现状 航空制造技术,2005年第5期86-89
[40]Denney P E,Fallara P M,Brown L E,et al.Hybrid Laser Weld Development for Shipbuilding Applications[R].Boston:Ship Production Symposium and Expo,2002
[41]张朝晖.ansys8.0热分析教程 北京:中国铁道出版社
[42]Tommi Jokinen,teppo Viherva,Hannu Ruujibwb.Welding of ship structural steel A36 using a Nd:YAG laser and gas-metal arc welding.JOURNAL OF LASRE AppLICATIONS,2000 vol.12(5):30-34
[43]张铜生 张富德.简明有限元法及应用.第一版.北京:地震出版社,1990
[44]顾兰 薛忠明等.激光深熔温度场数值模拟热源模型分析.电焊机,2004,34(9):4-7.
[45]刘建华 李志远 胡伦骥.激光深熔传热模型的研究.激光技术,1995,Vol.19(1):10-14.
[46]ANSYS在激光焊接温度场数值模拟中的应用 焊接技术,第35卷第5期2006年10月:6-9
[2]卢振洋 等基于ANSYS薄板GTAW焊接温度场数值模拟 微计算机信息2007年23卷21期291-292
[3]陈彦斌,徐庆鸿,苏彦东.激光-同轴电弧复合焊接热源焊接[J]焊接学报,1995 16(4):239-243
[4]刘黎明等 镁合金激光-TIG复合热源焊接热源模型的建立及其数值模拟机械工程学报2006年2月82-86
[5]张旭东等CO_2激光-MIG同轴复合焊方法及铝合金焊接的研究应用激光2005年2月1-3
[6]武传松.焊接热过程数值分析.哈尔滨:哈尔滨工业大学出版社,1990
[7]陈楚等.数值分析在焊接中的应用.上海:上海交通大学出版社,1985,1.80-82
[8]林得超.焊接过程应力应变特征及其控制的数值模拟.博士学位论文.西安交通大学 博士学位论文,1997
[9]樊丁.YAG激光与脉冲MIG复合[j].焊接学报,2002 23(5):160-166.
[10]潘际孪.二十一世纪焊接科学研究的展望.第九次全国焊接会议论文集.哈尔滨:黑龙江人民出版社,1999:D1-D17
[11]熊蜡森.焊接工程基础.第一版.北京:机械工业出版社,2002
[12]黄旺福,黄金刚.铝及铝合金焊接指南.第一版.湖南:湖南科学技术出版社,2004
[13]左铁川.高强铝合金的激光加工.第一版.北京:国防工业出版社,2002
[14]熊建钢 深熔激光焊接小孔和熔池形状数学模型及工艺参数ANN优化设计.[博士学位论文]。武汉:华中科技大学,2001
[15]张屹.激光深熔焊接小孔效应的理论和试验研究:[硕士学位论文].湖南:湖南大学,2002
[16]Remy Fabbro,Karim Chouf.Dynamical description of the keyhole in deep penetration laser welding.JOURNAL OF LASRE APPLICATIONS,2000 Vol(4):142-147
[17]T.Graf,H.Staufer.Laser-hybrid welding.Welding Journal,2003(1):42-48
[18]王威,李丽群,忘旭友等.激光电弧复合焊接技术.焊接,2004(3):6-9
[19]张志勇,田志凌,彭云.铝合金先进焊接工艺.焊接,2003(7):5-9
[20]曹丽杰.铝合金的激光焊接:[硕士学位论文]。哈尔滨工业大学,2001
[21]T.GRF,H.STAUFER.Laser Hybrid Welding Drivers VW Improvements.Welding Journal,2004,Vol(83):43-47
[22]T.Graf,H.Staufer.Laser-hybrid welding.Welding Journal,2003(1):42-48
[23]陈彦宾.激光-TIG复合热源焊接物理特性研究:[博士学位论文]。哈尔滨:哈尔滨工业大学,2003
[24]S.Kaierle,K.Bongard,M.Dahmen,R.Poprawe.Innovative Hybrid Welding Process in an Industrial Application.Section C-ICALEO:2000.91-98.
[25]张旭东,陈武柱.激光电弧同轴复合焊矩[z]中国:CN144661A,2003.
[26]STAUFER HERBERT.Laser-Hybrid Welding of Ships.Welding Journal,2004 Vol(83)39-43
[27]Matsuda J,Utsumi A,et al.TIG or MIG arc augmented laser welding of thick mild steel plate.Joining &Materials, 1988,1(1):31-34
[28]Jasnau Ulf,Hoffmann Jan,Seyffarth Peter.Nd:YAG-lascr-gas metal arc-hybrid welding:a chance for the use of the advantages of laser technology and flexible automation in shipbuilding and steel construction[R].RWIA,2002,
[29]GrafT,Staufer H.Laser-hybrid welding drives VW improvements[J].Welding Journal,2003,82(I):42-48
[30]Kairle S,bongard K,dahmen M,et al.Innovative Hybrid Welding Process in an Industrial Application[A].Procedings of the Laser Materials Processing Conference[C].Section C-ICALEO,2000:91-98.
[31]陈伯蠡.焊接冶金原理.第一版.北京:清华大学出版社,1991
[32]陈楚,汪建华,杨洪庆.非线性焊接热传导的有限元分析和计算.焊接学报,1983(3):139-148
[33]陈楚,汪建华,杨洪庆.水下焊接冷却特性的有限元分析.海洋工程,1983(4):34-38
[34]鹿安理,史清宇,赵海燕等.厚板焊接过程温度场、应力场的三维有限元数值模拟.中国机械工程,2001.12(2):183-186
[35]Y.Ueda.Analysis of thermal elastic-plastic stress and strain during welding.Trans.Japan Welding,1971,2(2):90-100
[36]J.Goldak.Thermal Stress Analysis of Welds.From melting point to room temperature.Pro.Theoretical Prediction in Joining and Welding(Osaka,Japan),1996:225-230
[37]蔡洪能 唐慕尧.TIG焊接温度场的有限元分析,机械工程学报,1996.32(2):34-39
[38]Paley Z,Hibbert P D.Computation of Temperation in Actual Weld Designs.Welding Journal 1975,54(11):385-392;
[39]吕高尚 董春林 激光电弧复合热源焊接研究及应用现状 航空制造技术,2005年第5期86-89
[40]Denney P E,Fallara P M,Brown L E,et al.Hybrid Laser Weld Development for Shipbuilding Applications[R].Boston:Ship Production Symposium and Expo,2002
[41]张朝晖.ansys8.0热分析教程 北京:中国铁道出版社
[42]Tommi Jokinen,teppo Viherva,Hannu Ruujibwb.Welding of ship structural steel A36 using a Nd:YAG laser and gas-metal arc welding.JOURNAL OF LASRE AppLICATIONS,2000 vol.12(5):30-34
[43]张铜生 张富德.简明有限元法及应用.第一版.北京:地震出版社,1990
[44]顾兰 薛忠明等.激光深熔温度场数值模拟热源模型分析.电焊机,2004,34(9):4-7.
[45]刘建华 李志远 胡伦骥.激光深熔传热模型的研究.激光技术,1995,Vol.19(1):10-14.
[46]ANSYS在激光焊接温度场数值模拟中的应用 焊接技术,第35卷第5期2006年10月:6-9