牵引电机定子引线与回路环电阻钎焊数值模拟
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摘要
以轨道车辆用牵引电机定子引线与回路环的电阻钎焊接头为研究对象,在有限元软件MSC.Marc中建立引线与回路环电阻钎焊过程热、电耦合分析的有限元模型,采用数值模拟的方法对引线与回路环电阻钎焊的焊接温度场和焊接热循环特征进行研究,并进行了试验验证。结果表明:引线与回路环无论是钎接过程中还是加热终了时刻,温度场都呈不对称形态,引线一侧高于回路环一侧。加热峰值出现在通电结束时刻,焊接区的最高温度并不在钎缝中心而是在钎缝前端,最高温区的温度比钎缝中心高出约30℃,钎缝末端位置的温度比钎缝中心低约30～60℃,将钎缝中心温度控制在700℃左右既能保证钎料熔化又能减少焊接温度对引线热影响区机械性能的影响。
The resistance brazed joint of traction motor stator lead and loop for rail vehicle were taken as the research subject. The thermal-electric coupling model for resistance brazing process of lead and loop were established in finite element software MSC. Marc. The characteristics of welding temperature field and thermal cycle of resistance brazing of lead wire and loop were investigated by numerical simulation and the result was verified by experiments further. The results show that the welding temperature field of lead and loop exhibit an asymmetrical characteristic either during the brazing process or at the end of heating and the temperature of lead wire is higher than that of loop. The temperature reaches the maximum at the end of heating and the highest temperature occurs in the front of brazing seam instead of the center of the brazing seam. Moreover,the temperature of maximum temperature zone is 30℃ higher than that of the brazing seam center, and the temperature of the end of the brazing seam is 30 ～60℃ lower than that of the brazing seam center. The temperature of the seam center is controlled at about 700℃, which can ensure the melting of solder and reduce the influence of welding temperature on the mechanical properties of the heat affected zone of the lead.
The resistance brazed joint of traction motor stator lead and loop for rail vehicle were taken as the research subject. The thermal-electric coupling model for resistance brazing process of lead and loop were established in finite element software MSC. Marc. The characteristics of welding temperature field and thermal cycle of resistance brazing of lead wire and loop were investigated by numerical simulation and the result was verified by experiments further. The results show that the welding temperature field of lead and loop exhibit an asymmetrical characteristic either during the brazing process or at the end of heating and the temperature of lead wire is higher than that of loop. The temperature reaches the maximum at the end of heating and the highest temperature occurs in the front of brazing seam instead of the center of the brazing seam. Moreover,the temperature of maximum temperature zone is 30℃ higher than that of the brazing seam center, and the temperature of the end of the brazing seam is 30 ～60℃ lower than that of the brazing seam center. The temperature of the seam center is controlled at about 700℃, which can ensure the melting of solder and reduce the influence of welding temperature on the mechanical properties of the heat affected zone of the lead.
引文
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[2]李进泽.异步牵引电机端环与导条钎焊技术[J].机车电传动,2001(2):31-33.
[3]常保华,都东,Zhou Y.铝合金电阻点焊过程的有限元模拟[J].焊接学报,2004,25(2):19-22.
[4]Lee S R,Choo Y J,Lee T Y,et al.Neuro-fuzzy algorthm for quality assurance of resistance spot welding[J].35th IAS Annual Meeting and World Conference on Industrial Application of Electrical Energy.Rome,2000:1210-1216.
[5]El-Gizawy A S,Wood R A.Numberical modeling of resistance brazing process behavior in joining electrical contact materials[J].Engineering Materials and Technology,1999,121(3):330-335.
[6]Tanaka Y,Yamaguchi T,Takeshita K.Numerical simulation of joining during the two-step resistance brazing[J].Welding International,2013,27(11):857-866.
[7]杨黎缝.铝合金电阻点焊熔核形成过程的数值模拟[D].吉林:吉林大学,2005.
[8]赵祖德,姚良均,郭鸿运,等.铜及铜合金材料手册[M].北京:科学出版社,1993.
[9]吴志生,杨新华,单平,等.铝合金点焊电极端面温度数值模拟[J].焊接学报,2004,25(6):15-19.
[10]赵熹华,冯吉才.压焊方法及设备[M].北京:机械工业出版社,2005.
[11]张培磊,丁敏,姚舜,等.两种铜磷钎料对紫铜钎焊的焊接性能和焊接组织对比[J].机械工程材料,2009,33(2):82-85.