带有联结件的电阻点焊新工艺研究
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摘要
电阻点焊因其生产率高、环境污染小、焊接质量高、易于实现自动化等特点,广泛应用于航空航天、汽车、农机及轻工家电等制造业。但传统电阻点焊也存在一定的缺陷,这主要包括:焊件表面有压痕;热影响区较大;焊核的大小与工件的厚度有关,当工件较薄时,焊核较小,连接强度低;电极磨损严重。
针对传统电阻点焊的不足,本文提出了带有联结件的电阻点焊新工艺,介绍了新工艺的焊接原理,以Q235钢板为试件对新工艺和传统工艺进行了试验对比分析。在试验过程中,对焊接质量进行了拉剪力检测和金相显微结构分析,证明带有联结件的电阻点焊新工艺与传统电阻点焊工艺相比有明显优越性,这包括焊点的表面压痕小、电极磨损小;热影响区小,焊核直径几乎与焊件的厚度无关;在达到相同的焊点强度时,若焊接时间相同,带有联结件的电阻点焊新工艺所需的焊接电流较小,可实现节能。其不足是有时在工件焊核边留下缝隙、有附加件。
The resistance spot welding (RSW) is widely used in manufacture of aerospace, automobile, agricultural machinery and other appliances due to its advantages of high productivity, low pollution, good weld quality, and easy to automation. However, the traditional RSW technology has the shortcomings of surface deformation, bigger HAZ, weld nugget depended on the thickness of the specimens , small weld nugget and low intensity for the thin workpiece , as well as the heavier electrode wear.
In this paper,a new technology of resistance spot welding with the joining element is proposed. The principle of the new technology is presented and the comparison tests with the traditional spot welding is performed using low carbon steel plates as the specimens. The weld quality of the welding joint was checked by the tensile-shear tests and the microstructure analysis. The results show that the new technology has the apparent advantages, having solved the problems that the traditional spot welding has, this includes the small surface deformation, low electrode wear, weld nugget diameter unrelated to the specimen thickness, and energy saving because the new spot welding technology with joining element requires lower welding current in the case of same weld quality acquired and same welding time used. The disadvantages of the new technology is that it needs a additional element and sometimes a gap is left beside the weld nugget.
针对传统电阻点焊的不足,本文提出了带有联结件的电阻点焊新工艺,介绍了新工艺的焊接原理,以Q235钢板为试件对新工艺和传统工艺进行了试验对比分析。在试验过程中,对焊接质量进行了拉剪力检测和金相显微结构分析,证明带有联结件的电阻点焊新工艺与传统电阻点焊工艺相比有明显优越性,这包括焊点的表面压痕小、电极磨损小;热影响区小,焊核直径几乎与焊件的厚度无关;在达到相同的焊点强度时,若焊接时间相同,带有联结件的电阻点焊新工艺所需的焊接电流较小,可实现节能。其不足是有时在工件焊核边留下缝隙、有附加件。
The resistance spot welding (RSW) is widely used in manufacture of aerospace, automobile, agricultural machinery and other appliances due to its advantages of high productivity, low pollution, good weld quality, and easy to automation. However, the traditional RSW technology has the shortcomings of surface deformation, bigger HAZ, weld nugget depended on the thickness of the specimens , small weld nugget and low intensity for the thin workpiece , as well as the heavier electrode wear.
In this paper,a new technology of resistance spot welding with the joining element is proposed. The principle of the new technology is presented and the comparison tests with the traditional spot welding is performed using low carbon steel plates as the specimens. The weld quality of the welding joint was checked by the tensile-shear tests and the microstructure analysis. The results show that the new technology has the apparent advantages, having solved the problems that the traditional spot welding has, this includes the small surface deformation, low electrode wear, weld nugget diameter unrelated to the specimen thickness, and energy saving because the new spot welding technology with joining element requires lower welding current in the case of same weld quality acquired and same welding time used. The disadvantages of the new technology is that it needs a additional element and sometimes a gap is left beside the weld nugget.
引文
1赵喜华,冯吉才.压焊方法及设备[M].北京:机械工业出版社,2005
2朱正行,严向明,王敏编著.电阻焊技术[M].北京:机械工业出版社,2000
3杜海龙.电阻点焊参数与焊接质量的相关性研究[D].内蒙古农业大学,2008
4 Pei Wu.Testing and Modeling of Machine Properties in Resistance Welding[D].Technical University of Denmark,2004,08
5刘桂梅.电阻点焊动态参数测试系统的设计开发[D].内蒙古农业大学,2006
6王福生.国内外电阻焊设备的发展[J].电焊机,2005,35(2):1-5
7卢本.近代电阻焊设备概论[J].现代焊接,2006,5:7-10
8吴继,张晨曙,罗贤星.镀锌钢板点焊形核机理的研究[J].南昌工程学院学报,2007,26(3):31-34
9赵熹华,徐国成,赵蕾.难焊金属材料电阻点焊熔核孕育处理的机理与效果[J].吉林工业大学自然科学学报,2001,31(4):17-20
10王亚荣,张忠典,冯吉才. AZ31B镁合金交流电阻点焊接头的力学性能及显微组织分析[J].机械工程学报,2004,40(5):131-135
11温家伶,黄志军,黄小军.薄板点焊工艺及性能研究[J].武汉造船,2000(1):15-17
12叶永青,黄金湘,龚晨琦.轿车前纵梁总成焊接生产工艺[J].电焊机2008,38(5):68-71
13彭永昌,高福全,范如源.铝合金薄壁件的点焊及表面处理工艺研究[J].现代制造工程,2003(1):47-49
14朱新民,濮存苏,杨宗洵.电梯不锈钢面板正面无压痕焊接新工艺的研究[J]焊接,2001(2):20-21
15马铁军,杨思乾.阀芯电阻焊[J].电焊机2003,33(9):45-47
16赵涛.镀锌钢板电阻点焊工艺研究[D]合肥工业大学2005,15-16
17崔怀香,方臣富.软开关逆变式点焊电源设计及工艺研究[J].电焊机2008,38(1):56-57
18王笑川,刘明宇.微型零件的精密焊接[J].航空精密制造技术2002,38(3):29-31
19林之宝,黎明,吴林.计算机在焊接中应用现状及发展前景[J].焊接,1998,(1):2-4l
20朱锦洪,黄石生,李发兴.点焊机器人焊接系统的控制研究[J].电焊机,1995,(l):14-17
21谢坚聂淦生电阻点焊研究进展[J].电焊机,1994,(1):1-8
22 C.L.Tsai,O.A.Jammal,J.C.Papritan .Modeling of Resistance Spot Weld Nugget Growth[J]. Weld Journal,1992,66(2):47s-53s
23 W. Zhang. Design and Implementation of Software for Resistance Welding Process Simulations[J]. Journal of Materials and Manufacturing, 2003, 112,(5):556-564.
24徐进,牛占文.球形电极条件下低碳钢电阻点焊的预压接触分析[J].汽车技术,2003(5):26-30
25杨小卫,朱茂桃,袁乐清.汽车车身结构点焊的数值模拟与试验[J].农业机械学报,2007(8):155-158.
26贾利兵.铝合金电阻点焊界面电阻行为的数值模拟[D],西安交通大学,2002
27谭佃龙,章三红.超低碳钢贝氏体钢焊接热影响区研究[J].焊接学报1996,17(3):139-144
28 M.Hamedi, H.Pashazadeh.Numerical study of nugget formation in resistance spot welding[J]. International journal of mechanics, 2008, 2(1), 11-15
29倪建东.车身铝合金板材中频点焊工艺的研究[D]北京工业大学,2008
30曹键,陈关龙,李永兵,张延松.轿车车身点焊信息计算机管理系统的开发[J]机械制造,2004,(08)
31 Primoz Podrzaj, Ivan Polajnar, Janez Diaci,etal. Expulsion detection system for resistance spot welding based on a neural network.2004[J]. Meas. Sci.technol,1995,(15):592-598
32 MajumdarA,Tien C L. Fractal network model for contact conductance[J].Journalof Heat Transfer,1991,113(8):516-525
33 Tskums Masnori,Shinke Noboru.Evaluation of function of spot welded joint using ultrasonic inspection(nondestructive evaluation on tension shearing strength with neural network)[J].Mechanics and Material Engineer,1996,39(10):626-632
34张君媛,刘震.汽车车门附件数据库系统的研究与开发[J]汽车技术,2002,(04)
35金丽华.电阻焊数据采集分析系统研究[D].甘肃工业大学,2004,30:1-4.
36 Oscar. Quality prediction of resistance spot welding joints of 304 austenitic stainless steel [J]. Marerials and Design 30(2009)68-77.
37 Johannes Ruisz . Jürgen Biber . Mario Loipetsberger. Quality evaluation in resistance spot welding by analyzing the weld fingerprint on metal bands by computer vision[J]. Int J Adv Manuf Technol 2007 (33): 952 960
38 S.R.SIN,S.MYANG. Fatigue analysis for a multi-lap spot welded joint of high strength steel using qusi static tensile-shear test[J]. International Journal of Automotive Technology .2008(9)81-86.
39 Wonseok Jung, Dongho Bae. Fatigue Design of Various Type Spot Welded LapJoints Using the Maximum Stress[J]. KSME International Journal ,2004.Vol. 18 (1): 106-113
40姚河清,张书朋,李凌.一种新的电阻点焊方法[J].机电工程技术2007,36(01):52-54
41 BY V. KARTHIK, K. V. KASIVISWANATHAN, K. LAHA. Determination of Gradients in Mechanical Properties of 2.25Cr-1Mo Weldments Using Shear-Punch Tests[J]. SUPPLEMENT TO THE WELDING JOURNAL, December 2002,265-S—267-S
42金龙存.图像处理在电阻点焊质量检测中的应用研究[D].内蒙古农业大学,2008
2朱正行,严向明,王敏编著.电阻焊技术[M].北京:机械工业出版社,2000
3杜海龙.电阻点焊参数与焊接质量的相关性研究[D].内蒙古农业大学,2008
4 Pei Wu.Testing and Modeling of Machine Properties in Resistance Welding[D].Technical University of Denmark,2004,08
5刘桂梅.电阻点焊动态参数测试系统的设计开发[D].内蒙古农业大学,2006
6王福生.国内外电阻焊设备的发展[J].电焊机,2005,35(2):1-5
7卢本.近代电阻焊设备概论[J].现代焊接,2006,5:7-10
8吴继,张晨曙,罗贤星.镀锌钢板点焊形核机理的研究[J].南昌工程学院学报,2007,26(3):31-34
9赵熹华,徐国成,赵蕾.难焊金属材料电阻点焊熔核孕育处理的机理与效果[J].吉林工业大学自然科学学报,2001,31(4):17-20
10王亚荣,张忠典,冯吉才. AZ31B镁合金交流电阻点焊接头的力学性能及显微组织分析[J].机械工程学报,2004,40(5):131-135
11温家伶,黄志军,黄小军.薄板点焊工艺及性能研究[J].武汉造船,2000(1):15-17
12叶永青,黄金湘,龚晨琦.轿车前纵梁总成焊接生产工艺[J].电焊机2008,38(5):68-71
13彭永昌,高福全,范如源.铝合金薄壁件的点焊及表面处理工艺研究[J].现代制造工程,2003(1):47-49
14朱新民,濮存苏,杨宗洵.电梯不锈钢面板正面无压痕焊接新工艺的研究[J]焊接,2001(2):20-21
15马铁军,杨思乾.阀芯电阻焊[J].电焊机2003,33(9):45-47
16赵涛.镀锌钢板电阻点焊工艺研究[D]合肥工业大学2005,15-16
17崔怀香,方臣富.软开关逆变式点焊电源设计及工艺研究[J].电焊机2008,38(1):56-57
18王笑川,刘明宇.微型零件的精密焊接[J].航空精密制造技术2002,38(3):29-31
19林之宝,黎明,吴林.计算机在焊接中应用现状及发展前景[J].焊接,1998,(1):2-4l
20朱锦洪,黄石生,李发兴.点焊机器人焊接系统的控制研究[J].电焊机,1995,(l):14-17
21谢坚聂淦生电阻点焊研究进展[J].电焊机,1994,(1):1-8
22 C.L.Tsai,O.A.Jammal,J.C.Papritan .Modeling of Resistance Spot Weld Nugget Growth[J]. Weld Journal,1992,66(2):47s-53s
23 W. Zhang. Design and Implementation of Software for Resistance Welding Process Simulations[J]. Journal of Materials and Manufacturing, 2003, 112,(5):556-564.
24徐进,牛占文.球形电极条件下低碳钢电阻点焊的预压接触分析[J].汽车技术,2003(5):26-30
25杨小卫,朱茂桃,袁乐清.汽车车身结构点焊的数值模拟与试验[J].农业机械学报,2007(8):155-158.
26贾利兵.铝合金电阻点焊界面电阻行为的数值模拟[D],西安交通大学,2002
27谭佃龙,章三红.超低碳钢贝氏体钢焊接热影响区研究[J].焊接学报1996,17(3):139-144
28 M.Hamedi, H.Pashazadeh.Numerical study of nugget formation in resistance spot welding[J]. International journal of mechanics, 2008, 2(1), 11-15
29倪建东.车身铝合金板材中频点焊工艺的研究[D]北京工业大学,2008
30曹键,陈关龙,李永兵,张延松.轿车车身点焊信息计算机管理系统的开发[J]机械制造,2004,(08)
31 Primoz Podrzaj, Ivan Polajnar, Janez Diaci,etal. Expulsion detection system for resistance spot welding based on a neural network.2004[J]. Meas. Sci.technol,1995,(15):592-598
32 MajumdarA,Tien C L. Fractal network model for contact conductance[J].Journalof Heat Transfer,1991,113(8):516-525
33 Tskums Masnori,Shinke Noboru.Evaluation of function of spot welded joint using ultrasonic inspection(nondestructive evaluation on tension shearing strength with neural network)[J].Mechanics and Material Engineer,1996,39(10):626-632
34张君媛,刘震.汽车车门附件数据库系统的研究与开发[J]汽车技术,2002,(04)
35金丽华.电阻焊数据采集分析系统研究[D].甘肃工业大学,2004,30:1-4.
36 Oscar. Quality prediction of resistance spot welding joints of 304 austenitic stainless steel [J]. Marerials and Design 30(2009)68-77.
37 Johannes Ruisz . Jürgen Biber . Mario Loipetsberger. Quality evaluation in resistance spot welding by analyzing the weld fingerprint on metal bands by computer vision[J]. Int J Adv Manuf Technol 2007 (33): 952 960
38 S.R.SIN,S.MYANG. Fatigue analysis for a multi-lap spot welded joint of high strength steel using qusi static tensile-shear test[J]. International Journal of Automotive Technology .2008(9)81-86.
39 Wonseok Jung, Dongho Bae. Fatigue Design of Various Type Spot Welded LapJoints Using the Maximum Stress[J]. KSME International Journal ,2004.Vol. 18 (1): 106-113
40姚河清,张书朋,李凌.一种新的电阻点焊方法[J].机电工程技术2007,36(01):52-54
41 BY V. KARTHIK, K. V. KASIVISWANATHAN, K. LAHA. Determination of Gradients in Mechanical Properties of 2.25Cr-1Mo Weldments Using Shear-Punch Tests[J]. SUPPLEMENT TO THE WELDING JOURNAL, December 2002,265-S—267-S
42金龙存.图像处理在电阻点焊质量检测中的应用研究[D].内蒙古农业大学,2008