1561铝合金薄板随焊干冰激冷变形控制
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摘要
目前随焊激冷技术存在装置复杂、占用空间大、冷却介质低效等缺点,为改善其在船舶制造业上的应用,提出随焊干冰激冷技术。采用数值模拟与试验分析相结合的方法研究随焊干冰激冷对铝合金薄板变形的控制。对喷嘴喷射干冰形成的冷源温度场进行测量。并基于测试结果建立冷源模型,实现了随焊干冰激冷的有限元数值模拟。通过研究冷却距离对残余应力和变形的控制效果,优化随焊干冰激冷工艺。研究表明,现有条件下最优的冷却距离约为40 mm。通过施加随焊干冰激冷最优工艺,纵向残余拉应力峰值减小46.9%,纵向压应力峰值减小40.8%,焊接变形量减小51.5%。理论及试验结果表明,随焊干冰激冷技术是一种控制薄板焊接应力及变形的有效手段,为随焊激冷技术在船舶制造业上的应用提供一个方向。
At present, with the disadvantages of complex equipment, large space, and inefficient cooling medium, the technology of welding with trailing cooling of driold has been proposed to improve its application in shipbuilding industry. The mean of combining numerical simulation and experimental analysis is implemented to study the distortion control of aluminum alloy sheet during welding with trailing cooling of drikold. The relevant experimental equipment is built to measure the cold source temperature field formed by spraying from nozzle after drikold particles. The established cold source model based on the result of tests is substituted into the corresponding finite element analysis in order to simulate welding process. The effect of cooling distance on residual stress and distortion is studied, and the welding with trailing cooling of drikold is optimized. The results show that the optimal cooling distance is about 40 mm under existing conditions. The longitudinal residual tensile stress decreases by 46.9%, the longitudinal compressive stress decreases by 40.8%, and the welding distortion decreases by 51.5%. The theoretical and experimental results show that the welding with trailing cooling of drikold technology is an effective method to control the welding stress and distortion of thin sheet,which provides a direction for the application of the welding technology in shipbuilding industry.
At present, with the disadvantages of complex equipment, large space, and inefficient cooling medium, the technology of welding with trailing cooling of driold has been proposed to improve its application in shipbuilding industry. The mean of combining numerical simulation and experimental analysis is implemented to study the distortion control of aluminum alloy sheet during welding with trailing cooling of drikold. The relevant experimental equipment is built to measure the cold source temperature field formed by spraying from nozzle after drikold particles. The established cold source model based on the result of tests is substituted into the corresponding finite element analysis in order to simulate welding process. The effect of cooling distance on residual stress and distortion is studied, and the welding with trailing cooling of drikold is optimized. The results show that the optimal cooling distance is about 40 mm under existing conditions. The longitudinal residual tensile stress decreases by 46.9%, the longitudinal compressive stress decreases by 40.8%, and the welding distortion decreases by 51.5%. The theoretical and experimental results show that the welding with trailing cooling of drikold technology is an effective method to control the welding stress and distortion of thin sheet,which provides a direction for the application of the welding technology in shipbuilding industry.
引文
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[15]杨建国,周号,雷靖,等.焊接应力与变形数值模拟领域的若干关键问题[J].焊接,2014(3):8-17.YANG Jianguo,ZHOU Hao,LEI Jing,et al.Key scientific problems in numerical simulation field of welding residual stress and distortion[J].Welding,2014(3):8-17.
[16]JOHN G,ADITYA C,MALCOLM B,et al.A new finite element model for welding heat sources[J].Metallurgical Transaction B,1984,15(2):302-306.
[17]VAN D A E M.Local cooling during welding:Prediction and control of residual stresses and buckling distortion[D].Delft:Technische University of Delft,2007.
[2]周广涛,黄海瀚,方洪渊.随焊超声波激振法控制铝合金薄板焊接应力及变形[J].中国有色金属学报,2014,24(4):919-925.ZHOU Guangtao,HUANG Haihan,FANG Hongyuan.Controlling welding stress and distortion of aluminum alloy sheet by welding with trailing ultrasonic vibration method[J].The Chinese Journal of Nonferrous Metals,2014,24(4):919-925.
[3]刘西霞,尹存宏,刘维岗.基于随焊气体动态冷却方法的钛合金薄板激光焊接变形试验研究[J].热加工工艺,2017,46(13):57-60.LIU Xixia,YIN Cunhong,LIU Weigang.Experimental study on laser weld deformation of titanium alloy sheet based on synchronous gas cooling during welding[J].Hot Working Technology,2017,46(13):57-60.
[4]韩德成,陈东方,张铁浩,等.随焊激冷法控制高速列车地板焊接变形的数值模拟[J].电焊机,2016,46(2):74-77.HAN Decheng,CHEN Dongfang,ZHANG Tiehao,et al.Numerical simulation on controlling high-speed train floor welding deformation by means of welding with chilling[J].Electric Welding Machine,2016,46(2):74-77.
[5]NAGY T.Investigation of thermal techniques to mitigate buckling distortion in welding panels[D].Cranfield:Cranfield University,2012.
[6]LI J.Henry Granjon Prize competition 2005“Design and structural integrity”localized thermal tensioning technique to prevent buckling distortion[J].Welding in the World,2005,49(11-12):4-14.
[7]JI S,YANG Z,WEN Q,et al.Effect of trailing intensive cooling on residual stress and welding distortion of friction stir welded 2060 Al-Li alloy[J].High Temperature Materials&Processes,2018,37(5):397-403.
[8]OKANO S,MOCHIZUKI M,TOYODA M,et al.Effect of welding conditions on reduction in angular distortion by welding with trailing heat sink[J].Science&Technology of Welding&Joining,2013,17(4):264-268.
[9]刘西霞.钛合金薄板激光焊接变形控制研究[D].长沙:湖南大学,2014.LIU Xixia.Study on the control of laser welding deformation of titanium alloy thin sheet[D].Changsha:Hunan University,2014.
[10]STARON P,KOCAK M,WILLIAMS S,et al.Residual stress in friction stir-welded Al sheets[J].Applied Physics A,2004,350(1):491-493.
[11]HOVANSKI Y,CARSLEY J,CLARKE K,et al.Friction-stir welding and processing[J].Materials Society,2015,67(5):996-999.
[12]杨占鹏.航空铝合金的热-冷源辅助MIG焊工艺及变形控制[D].沈阳:沈阳航空航天大学,2018.YANG Zhanpeng.Distortion control and process with hot-cold source during aero aluminum MIG welding[D].Shenyang:Shenyang Aerospace University,2018.
[13]谢浩.随焊干冰激冷控制焊接应力与变形研究[D].杭州:浙江工业大学,2017.XIE Hao.Control of welding residual and strain by welding with trailing cooling of drikold[D].Hangzhou:Zhejiang University of Technology,2017.
[14]刘雪松,闫德俊,杨建国,等.有限元分析热-力学参量对焊接残余应力峰值特征的影响[J].焊接学报,2010,31(7):27-30.LIU Xuesong,YAN Dejun,YANG Jianguo,et al.Effect of thermomechanical parameters on hump feature of welding residual stress by finite element analysis[J].Transactions of the China Welding Institution,2010,31(7):27-30.
[15]杨建国,周号,雷靖,等.焊接应力与变形数值模拟领域的若干关键问题[J].焊接,2014(3):8-17.YANG Jianguo,ZHOU Hao,LEI Jing,et al.Key scientific problems in numerical simulation field of welding residual stress and distortion[J].Welding,2014(3):8-17.
[16]JOHN G,ADITYA C,MALCOLM B,et al.A new finite element model for welding heat sources[J].Metallurgical Transaction B,1984,15(2):302-306.
[17]VAN D A E M.Local cooling during welding:Prediction and control of residual stresses and buckling distortion[D].Delft:Technische University of Delft,2007.