基于移动坐标系的汽车轮辋FSW传热模型构建与分析
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摘要
为模拟A356铝合金汽车轮辋的搅拌摩擦焊接,利用移动坐标系坐标转换方法,基于傅里叶定律定义了引入焊接速度项的热传导控制方程以降低建模难度。摩擦产热采用剪切摩擦模型,根据能量守恒定律,通过微积分方程并考虑了功能转化的效率,合理推导出轴肩与搅拌针作用域的产热公式,并根据轮辋对称结构简化计算模型,进而建立轮辋的搅拌摩擦焊接传热模型。通过相同焊接工艺条件下轮辋焊缝轮廓形貌模拟与试验结果对比,验证了建立的搅拌摩擦焊接传热模型的有效性和准确性,可用于优化轮辋焊接工艺参数和研究轮辋搅拌摩擦焊接机制。
For simulation of friction stir welded A356 aluminum alloy wheel rim,the coordinate transformation method about the moving coordinate system was used based on Fourier law to define the heat conduction governing equation containing the term of welding speed,which was introduced to reduce the modeling difficulty.Friction heat production used the shear friction model,according to the law of conservation of energy,the calculus equation considering the function conversion efficiency was used to deduce the reasonable heat production formula of the shoulder and stir tool,and according to the rim symmetric structure,calculation model was simplified,and heat transfer model of friction stir welding rim was established.The comparison of the rim weld profile morphology simulation under the condition of the same welding process with the experimental results verifies the effectiveness and accuracy of friction stir welding heat transfer model,which can be used to optimize the rim welding process parameters and to understand the welding mechanism of friction stir welded wheel rim.
For simulation of friction stir welded A356 aluminum alloy wheel rim,the coordinate transformation method about the moving coordinate system was used based on Fourier law to define the heat conduction governing equation containing the term of welding speed,which was introduced to reduce the modeling difficulty.Friction heat production used the shear friction model,according to the law of conservation of energy,the calculus equation considering the function conversion efficiency was used to deduce the reasonable heat production formula of the shoulder and stir tool,and according to the rim symmetric structure,calculation model was simplified,and heat transfer model of friction stir welding rim was established.The comparison of the rim weld profile morphology simulation under the condition of the same welding process with the experimental results verifies the effectiveness and accuracy of friction stir welding heat transfer model,which can be used to optimize the rim welding process parameters and to understand the welding mechanism of friction stir welded wheel rim.
引文
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[2]武守辉,陈思杰,牛济泰,等.汽车制造中铝和钢异种金属间的点焊研究[J].热加工工艺,2013,42(11):17-20.
[3]蒋玉秀,王丽君.汽车工业中的铝合金及其焊接技术[J].电焊机,2012,42(4):109-112.
[4]北京赛福斯特技术有限公司.中国汽车制造工业搅拌摩擦焊技术应用[J].现代焊接,2011(7):24-25.
[5]张云开,路平,马峰,等.轮辋扩口成形过程的有限元分析[J].热加工工艺,2015,44(1):112-115.
[6]刘守法,蔡云,李春风,等.6061-T6铝合金塑流摩擦点焊技术的改进[J].特种铸造及有色合金,2015,35(1):110-112.
[7]张朝许.基于Comsol的汽车轮毂的搅拌摩擦焊接模拟[J].热加工工艺,2013,42(19):202-204.
[8]张宏阁,郭仓库.汽车轮毂搅拌摩擦焊的数值模拟[J].电焊机,2014,44(10):90-93.
[9]张昭,吴奇,张洪武.搅拌针对搅拌摩擦焊接搅拌区晶粒影响研究[J].兵器材料科学与工程,2014,37(5):32-35.
[10]梁代春,程飞.基于Norton模型汽车轮毂热诱导长效蠕变分析[J].热加工工艺,2013,42(18):164-166.
[11]CHOI I Y,KANG Y J,KIM A,et al.Development of the twopiece aluminum wheels using the friction stir welding[J].Journal of Manufacturing Engineering Technology,2013,22(4):700-707.
[12]郭柱,朱浩,崔少朋,等.7075铝合金搅拌摩擦焊接头温度场及残余应力场的有限元模拟[J].焊接学报,2015,36(2):92-96.