搅拌摩擦焊搅拌头疲劳寿命的模拟研究
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摘要
针对搅拌摩擦焊稳定焊接阶段,建立搅拌头受力模型与有限元分析模型,由计算结果可知,在稳定焊接阶段,前行处搅拌头根部为搅拌头薄弱部位,在垂直于搅拌头轴线方向,正侧面受拉应力,背面受压应力,分别为115.5, 127.5 MPa,若设计不当易从此处断裂。在此基础上结合Ramberg-Osgood模型,采用应变-寿命(E-N)法,对搅拌头进行疲劳寿命估算。结果表明,在当前焊接工艺参数下,搅拌头疲劳循环寿命为3.896×10~9次,可焊接6.487 25×10~4 m,不会出现疲劳断裂。结合实际生产中搅拌头并未出现断裂这一现象,今后在搅拌头设计中应更多考虑搅拌头焊接时的粘着磨损现象。
A mechanical model and finite element analysis model was established in the friction stir welding stable welding phase. The calculation result indicated that, the forward roots of the tool was the weakest parts of stir head in stable welding stage. In the direction perpendicular to the axis of the tool, the positive side had tensile stress and compressive stress on the back, respectively was 115.5 MPa, 127.5 MPa. Pin tool could fail from the root if improper design was adopted. On this basis, combined with the Ramberg-Osgood model, the strain-life(E-N) method was used to estimate the fatigue life of the agitator. The results showed that using the current process parameters, the fatigue cycle life of the tool was 3.896 248 905×109 seconds, and could be carried out without fatigue fracture for6.487 25 m. Considering that the tools did not break during the actual production, more attention should be paid to the adhesive wear phenomenon during the welding of the mixing head in the future design of the tools.
A mechanical model and finite element analysis model was established in the friction stir welding stable welding phase. The calculation result indicated that, the forward roots of the tool was the weakest parts of stir head in stable welding stage. In the direction perpendicular to the axis of the tool, the positive side had tensile stress and compressive stress on the back, respectively was 115.5 MPa, 127.5 MPa. Pin tool could fail from the root if improper design was adopted. On this basis, combined with the Ramberg-Osgood model, the strain-life(E-N) method was used to estimate the fatigue life of the agitator. The results showed that using the current process parameters, the fatigue cycle life of the tool was 3.896 248 905×109 seconds, and could be carried out without fatigue fracture for6.487 25 m. Considering that the tools did not break during the actual production, more attention should be paid to the adhesive wear phenomenon during the welding of the mixing head in the future design of the tools.
引文
[1]刘红伟,王法科,王冬生,等. 5A06铝合金焊接接头性能研究[J].兵器材料科学与工程, 2009, 32(2):72-6.
[2]赵海洋.铝合金搅拌摩擦焊接接头组织及疲劳断裂行为研究[D].天津:天津大学, 2010.
[3] Buffa G, Hua J, Shivpuri R, et al. A continuum based fem model for friction stir welding-model development[J]. Materials Science&Engineering A, 2006, 419(1):389-396.
[4]姬书得,杨鹏,张利国,等.搅拌摩擦焊搅拌头疲劳失效的模拟研究[J].北京理工大学学报, 2015(7):677-681.
[5]马晓飞.搅拌头形状及时效处理对铝合金接头性能的影响[D].甘肃兰州:兰州理工大学, 2017.
[6]严铿,曹亮,陈华斌.搅拌头倾角对FSW成形和接头力学性能的影响[J].焊接学报, 2005, 26(12):35-38.
[7] Rai R, De A, Bhadeshia HKDH, et al. Review:friction stir welding tools[J]. Science&Technology of Welding&Joining, 2011, 16(4):325-342.
[8]周利,刘会杰,刘鹏.搅拌头受力模型及应用[J].焊接学报,2009, 30(3):93-96.
[9]朱宗元.我国热作模具钢性能数据集[J].机械工程材料, 2001, 25(11):39-42.
[10] Zhang Z, Zhang H W. Numerical studies on controlling of process parameters in friction stir welding[J]. Journal of Materials Processing Tech, 2009, 209(1):241-270.
[11] Ramberg W, Osgood W R. Description of stress-strain curves by three parameters[J]. Technical Note, 1943(902).
[12] Hill H N. Determination of stress-strain relations from “offset”yield strength values[J]. Pediatrics, 1944, 6(1):93-97.
[13] Roessle M L, Fatemi A. Strain-controlled fatigue properties of steels and some simple approximations[J]. International Journal of Fatigue, 2000, 22(6):495-511.
[2]赵海洋.铝合金搅拌摩擦焊接接头组织及疲劳断裂行为研究[D].天津:天津大学, 2010.
[3] Buffa G, Hua J, Shivpuri R, et al. A continuum based fem model for friction stir welding-model development[J]. Materials Science&Engineering A, 2006, 419(1):389-396.
[4]姬书得,杨鹏,张利国,等.搅拌摩擦焊搅拌头疲劳失效的模拟研究[J].北京理工大学学报, 2015(7):677-681.
[5]马晓飞.搅拌头形状及时效处理对铝合金接头性能的影响[D].甘肃兰州:兰州理工大学, 2017.
[6]严铿,曹亮,陈华斌.搅拌头倾角对FSW成形和接头力学性能的影响[J].焊接学报, 2005, 26(12):35-38.
[7] Rai R, De A, Bhadeshia HKDH, et al. Review:friction stir welding tools[J]. Science&Technology of Welding&Joining, 2011, 16(4):325-342.
[8]周利,刘会杰,刘鹏.搅拌头受力模型及应用[J].焊接学报,2009, 30(3):93-96.
[9]朱宗元.我国热作模具钢性能数据集[J].机械工程材料, 2001, 25(11):39-42.
[10] Zhang Z, Zhang H W. Numerical studies on controlling of process parameters in friction stir welding[J]. Journal of Materials Processing Tech, 2009, 209(1):241-270.
[11] Ramberg W, Osgood W R. Description of stress-strain curves by three parameters[J]. Technical Note, 1943(902).
[12] Hill H N. Determination of stress-strain relations from “offset”yield strength values[J]. Pediatrics, 1944, 6(1):93-97.
[13] Roessle M L, Fatemi A. Strain-controlled fatigue properties of steels and some simple approximations[J]. International Journal of Fatigue, 2000, 22(6):495-511.