汽车白车身零部件激光三维切割与搭接焊研究
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摘要
激光加工技术已广泛应用于汽车白车身及其零部件制造,尤其是激光切割与焊接在国外已逐渐成为车身零部件制造的标准加工工艺。激光焊接、切割技术虽然在国内取得了长足的发展,但在汽车制造方面的应用与国外尚存在较大差距,目前主要还是引进成套激光加工设备、生产线和工艺技术,用于汽车拼焊板,车身组件的焊接和切割。这阻碍了激光这一高新技术的应用推广,降低了激光产业化水平。为提升我国汽车制造的先进技术能力,在更广范围和更深层次上,加快激光加工在汽车制造业的应用与发展。首先要加强激光切割焊接汽车车身及其零部件的基础理论及工艺技术研究,其次要加快其成套设备的研制。
本文综述了国内外研究现状,从车身的激光切割焊接实际应用出发,发现关键问题：在车身的三维激光切割中的空间狭窄位置切割头易与工件发生碰撞、工件拐角处易产生过烧、工件变形产生超程报警等；在车身激光焊接中,某些空间狭窄焊接部位焊接头也易与工件或夹具产生干涉、两车身零部件搭接位置因工件变形或夹持力度不够易产生较大的间隙致使无法进行熔焊连接、车身焊接部位激光焊缝长度和间距的制定无章可循、各种新材料在车身上的应用使得焊接难度增加等等。针对上述关键问题,本文从理论和试验上展开了全面研究。
首先,基于某一车型的车门和侧围工件的结构与工艺特点,并兼顾生产单元的柔性及安全性,对生产单元进行了布局总体设计和主要设备的选型。重点分析和解决了三维激光切割过程中的碰撞、工件变形、转角过烧等难题。提出了激光型式(脉冲激光和连续激光)的选择原则。并通过试验的方法研究了三维激光切割工艺参数如激光功率、切割速度、辅助气体压力、脉冲频率、占空比、光束入射角及焦点位置等对切割质量的影响；从切缝宽度、切割面粗糙度、切割面波纹、挂渣及热影响层深度等方面对切割质量进行了评定。通过对试验结果的分析,总结出了工艺参数对切割质量的影响规律。
其次,对激光焊接熔池特性进行了数值计算,分析了工艺参数对熔池形状及温度分布的影响。针对车身高强镀锌钢、镀锌钢、低碳钢以及铝合金等车身板材进行了光纤激光与C02激光搭接焊试验。研究了异种材料高功率光纤激光与C02激光搭接焊接头的成形特性和力学性能情况,以控制和优化车身零部件激光焊接质量。结果表明,采用光纤激光与CO2激光焊接时,焊缝形貌和接头性能均存在一定的差异,且光纤激光的焊接性能较CO2激光好。此外,在相同参数下进行异种板材激光搭接焊时,板间间隙大小、两板上下层的相对位置对焊接性能也有一定的影响。
随后,针对汽车白车身零部件激光搭接焊的结构特点和镀锌板搭接焊的难点,分析了激光光束入射角、板间间隙和焊缝布置形式等对接头焊接性能的影响。并研究了基于不同板材组合的搭接接头和各种影响因素下的临界光束入射角和极限可焊板间间隙。结果表明,板材厚度、焊缝熔宽等对临界光束入射角与极限板间间隙都有一定的影响。板材厚度较大时,光束入射角不宜太大,而板间间隙可适当增大；焊缝熔宽较窄时,光束入射角可适当增大,而板间间隙不能太大。此外,板间间隙与光束入射角也相互影响,板间间隙较小时,光束入射角不宜太大。当被焊试件规格尺寸和焊缝总长度不变时,以“短长度与多段数”形式进行焊缝布置的接头表面形貌和力学性能均较好。
最后,对激光焊与电阻点焊的性能进行了比较分析。针对同一板材搭接接头,设计了不同长度的激光焊缝,通过对各长度焊缝的接头进行力学性能比较,得出与一个电阻点焊性能相当的激光焊缝长度,并以此长度作为激光焊的最短焊缝长度。同时,分析了不同板厚、不同材质、不同焊缝表面熔宽以及异种板材的两板相对位置等因素对最短激光焊缝长度制定的影响。结果表明,板材厚度与焊缝表面熔宽不同时,最短激光焊缝长度取值不同；对于厚度和材质相近的异种板材搭接接头,两板的上下相对位置对激光焊缝长度的制定影响不大。此外,基于某一车型的车门零部件进行了激光焊与电阻焊对比试验。结果表明,采用激光焊时,焊接速度及车门整体静态强度显著高于电阻点焊,且激光焊接过程体现出更高的柔性。同时,激光焊接头的金相组织较电阻点焊细小均匀,显微硬度高于电阻点焊接头,抗腐蚀性能也优于电阻点焊接头。
Laser processing technology has been widely used in auto body-in-white and auto body parts manufacturing, especially the laser cutting and welding technology has gradually become standard process of auto body-in-white manufacturing in overseas. Although laser welding and cutting technology have grown rapidly in mainland, there still exists a great gap in the application of car manufacturing compared with foreign countries. In current situation, the complete laser processing equipments, production line and processing technology are mainly introduced for welding and cutting of tailor-welded blanks and auto body components from overseas. These hindered the promotion of laser technology application and reduced the level of the laser industry. In order to enhance our advanced technology and capabilities of auto manufacturing and accelerate the development of laser processing technology in auto manufacturing industry at a deeper level and a broader scope, first, the basic theory and technology of laser cutting and welding of auto body parts should be enhanced, and then the research of complete laser processing equipments should be accelerated.
In this paper, the research situation at home and abroad was reviewed. From the application of laser cutting and welding in auto body, the key issues were detected as shown the following:in the 3D laser cutting process of auto body, the cutting head in narrow spatial location easily collides with the workpiece, the workpiece corner is easy to be over-burnt, and the workpiece deformation causes over-travel alarm etc. In the laser welding process of auto body, the welding head in narrow spatial location also easily interferes with the workpiece or the fixture, two parts of auto body can't be welded to connect as a result of large gap due to workpiece deformation or not enough clamping force at overlap location, the laser length and space of welding seam at auto body welding position are determined with no description, and a variety of new materials used for auto body make more difficult to weld and so on. In order to find practical solutions to these problems, a comprehensive research from theory and experiment was carried out in this paper.
First, with the door and side panel as an example, the structure and process were analyzed taking flexibility and security into consideration, the overall layout of laser cutting and welding production unit of auto body was designed and the main types of equipments were chosen. The problems during the 3D laser cutting process, such as collision, deformation of the workpiece, the corner over-burn were analyzed and solved. The selection principle of laser form (pulse or CW laser) was proposed. The influence of 3D laser cutting process parameters such as laser power, cutting speed, assistant gas pressure, pulse frequency, the beam incident angle and the focus position on cutting quality was studied by testing. And the cutting quality from the terms of the kerf width, cutting roughness, cutting waviness and heat affected zone width and so on was evaluated. Through analysis of test results, the rules of process parameters on cutting quality were summarized.
Secondly, the characteristics of laser welding pool were numerical calculated, and the influence of process parameters on welding pool shape and temperature distribution was analyzed. The high-power fiber laser and CO2 laser welding experiments on automotive dissimilar materials such as high-strength galvanized steels, galvanized steels and common cold rolled automotive plates were carried out, and then their welding performance were compared and analyzed. The high-power fiber laser lap-welding joint forming properties and mechanical properties of heterogeneous materials were studied, so as to control and optimize the craft quality of fiber laser welding of auto body. The results show that when applying fiber laser and CO2 laser to weld respectively, the morphology and properties of welding joint have some differences, and the welding performance is much better under fiber laser welding condition. In addition, when welding the lap joint of dissimilar plates under the same parameters, the relative position between two plates has a certain effect on the welding performance.
Then, for the structural characteristics of laser Welding of auto body-in-white and the difficulties of lap welding of galvanized sheets, the influence of incident angle of laser beam, the plates space and the welding layout on the mechanical properties of the welded joint were analyzed. And the critical incident angle and the limit welding plates space in different lap joints and other effecting factors condition were studied. The results showed that plates thickness, weld width have a certain impact on the critical beam incident angle and the limit plates space. When plates thickness is large, the beam incident angle should not be too large, but the plates space may be increased appropriately. And when the weld width is narrow, the beam incident angle can be properly increased, but the plates space can't be too large. In addition, the plates space and the beam incident angle are mutually influenced. When plates space is small, the beam incident angle should not be too big. When the size of workpiece and the total length of welding seam are constant, the surface morphology and the mechanical properties of the lap joint arranged according the weld seam layout principle "short length and multi section" are good.
Finally, the performance of laser welding and resistance spot welding were compared. For the same plate's lap joint, designing different length of laser seam and through comparing the mechanical properties of weld joints with different seam length, one considerable welding seam was obtained. The influence of laser welding seam length on the mechanical properties of the lap joint was summarized. And the influence such as different thickness, different plates, different weld pool width, and relative position of heterogeneous plates and so on also were analyzed. The results showed that when the plate thickness and weld pool width are not the same, the laser weld length is different. For the lap joint of heterogeneous plates with similar thickness and material, their relative position has little impact on determining the shortest length of welding seam. In addition, based on the door parts of a vehicle, a comparison test between laser welding and resistance welding was carried out. Results found that under laser welding condition, the welding speed and the overall static stiffness of the door were higher, and the laser welding process reflected a higher flexibility. Simultaneously, results also showed that compared with the resistance spot welding joint, the microstructure of laser welding joint is more even and smaller, the hardness is higher, and the corrosion resistance is better.
本文综述了国内外研究现状,从车身的激光切割焊接实际应用出发,发现关键问题：在车身的三维激光切割中的空间狭窄位置切割头易与工件发生碰撞、工件拐角处易产生过烧、工件变形产生超程报警等；在车身激光焊接中,某些空间狭窄焊接部位焊接头也易与工件或夹具产生干涉、两车身零部件搭接位置因工件变形或夹持力度不够易产生较大的间隙致使无法进行熔焊连接、车身焊接部位激光焊缝长度和间距的制定无章可循、各种新材料在车身上的应用使得焊接难度增加等等。针对上述关键问题,本文从理论和试验上展开了全面研究。
首先,基于某一车型的车门和侧围工件的结构与工艺特点,并兼顾生产单元的柔性及安全性,对生产单元进行了布局总体设计和主要设备的选型。重点分析和解决了三维激光切割过程中的碰撞、工件变形、转角过烧等难题。提出了激光型式(脉冲激光和连续激光)的选择原则。并通过试验的方法研究了三维激光切割工艺参数如激光功率、切割速度、辅助气体压力、脉冲频率、占空比、光束入射角及焦点位置等对切割质量的影响；从切缝宽度、切割面粗糙度、切割面波纹、挂渣及热影响层深度等方面对切割质量进行了评定。通过对试验结果的分析,总结出了工艺参数对切割质量的影响规律。
其次,对激光焊接熔池特性进行了数值计算,分析了工艺参数对熔池形状及温度分布的影响。针对车身高强镀锌钢、镀锌钢、低碳钢以及铝合金等车身板材进行了光纤激光与C02激光搭接焊试验。研究了异种材料高功率光纤激光与C02激光搭接焊接头的成形特性和力学性能情况,以控制和优化车身零部件激光焊接质量。结果表明,采用光纤激光与CO2激光焊接时,焊缝形貌和接头性能均存在一定的差异,且光纤激光的焊接性能较CO2激光好。此外,在相同参数下进行异种板材激光搭接焊时,板间间隙大小、两板上下层的相对位置对焊接性能也有一定的影响。
随后,针对汽车白车身零部件激光搭接焊的结构特点和镀锌板搭接焊的难点,分析了激光光束入射角、板间间隙和焊缝布置形式等对接头焊接性能的影响。并研究了基于不同板材组合的搭接接头和各种影响因素下的临界光束入射角和极限可焊板间间隙。结果表明,板材厚度、焊缝熔宽等对临界光束入射角与极限板间间隙都有一定的影响。板材厚度较大时,光束入射角不宜太大,而板间间隙可适当增大；焊缝熔宽较窄时,光束入射角可适当增大,而板间间隙不能太大。此外,板间间隙与光束入射角也相互影响,板间间隙较小时,光束入射角不宜太大。当被焊试件规格尺寸和焊缝总长度不变时,以“短长度与多段数”形式进行焊缝布置的接头表面形貌和力学性能均较好。
最后,对激光焊与电阻点焊的性能进行了比较分析。针对同一板材搭接接头,设计了不同长度的激光焊缝,通过对各长度焊缝的接头进行力学性能比较,得出与一个电阻点焊性能相当的激光焊缝长度,并以此长度作为激光焊的最短焊缝长度。同时,分析了不同板厚、不同材质、不同焊缝表面熔宽以及异种板材的两板相对位置等因素对最短激光焊缝长度制定的影响。结果表明,板材厚度与焊缝表面熔宽不同时,最短激光焊缝长度取值不同；对于厚度和材质相近的异种板材搭接接头,两板的上下相对位置对激光焊缝长度的制定影响不大。此外,基于某一车型的车门零部件进行了激光焊与电阻焊对比试验。结果表明,采用激光焊时,焊接速度及车门整体静态强度显著高于电阻点焊,且激光焊接过程体现出更高的柔性。同时,激光焊接头的金相组织较电阻点焊细小均匀,显微硬度高于电阻点焊接头,抗腐蚀性能也优于电阻点焊接头。
Laser processing technology has been widely used in auto body-in-white and auto body parts manufacturing, especially the laser cutting and welding technology has gradually become standard process of auto body-in-white manufacturing in overseas. Although laser welding and cutting technology have grown rapidly in mainland, there still exists a great gap in the application of car manufacturing compared with foreign countries. In current situation, the complete laser processing equipments, production line and processing technology are mainly introduced for welding and cutting of tailor-welded blanks and auto body components from overseas. These hindered the promotion of laser technology application and reduced the level of the laser industry. In order to enhance our advanced technology and capabilities of auto manufacturing and accelerate the development of laser processing technology in auto manufacturing industry at a deeper level and a broader scope, first, the basic theory and technology of laser cutting and welding of auto body parts should be enhanced, and then the research of complete laser processing equipments should be accelerated.
In this paper, the research situation at home and abroad was reviewed. From the application of laser cutting and welding in auto body, the key issues were detected as shown the following:in the 3D laser cutting process of auto body, the cutting head in narrow spatial location easily collides with the workpiece, the workpiece corner is easy to be over-burnt, and the workpiece deformation causes over-travel alarm etc. In the laser welding process of auto body, the welding head in narrow spatial location also easily interferes with the workpiece or the fixture, two parts of auto body can't be welded to connect as a result of large gap due to workpiece deformation or not enough clamping force at overlap location, the laser length and space of welding seam at auto body welding position are determined with no description, and a variety of new materials used for auto body make more difficult to weld and so on. In order to find practical solutions to these problems, a comprehensive research from theory and experiment was carried out in this paper.
First, with the door and side panel as an example, the structure and process were analyzed taking flexibility and security into consideration, the overall layout of laser cutting and welding production unit of auto body was designed and the main types of equipments were chosen. The problems during the 3D laser cutting process, such as collision, deformation of the workpiece, the corner over-burn were analyzed and solved. The selection principle of laser form (pulse or CW laser) was proposed. The influence of 3D laser cutting process parameters such as laser power, cutting speed, assistant gas pressure, pulse frequency, the beam incident angle and the focus position on cutting quality was studied by testing. And the cutting quality from the terms of the kerf width, cutting roughness, cutting waviness and heat affected zone width and so on was evaluated. Through analysis of test results, the rules of process parameters on cutting quality were summarized.
Secondly, the characteristics of laser welding pool were numerical calculated, and the influence of process parameters on welding pool shape and temperature distribution was analyzed. The high-power fiber laser and CO2 laser welding experiments on automotive dissimilar materials such as high-strength galvanized steels, galvanized steels and common cold rolled automotive plates were carried out, and then their welding performance were compared and analyzed. The high-power fiber laser lap-welding joint forming properties and mechanical properties of heterogeneous materials were studied, so as to control and optimize the craft quality of fiber laser welding of auto body. The results show that when applying fiber laser and CO2 laser to weld respectively, the morphology and properties of welding joint have some differences, and the welding performance is much better under fiber laser welding condition. In addition, when welding the lap joint of dissimilar plates under the same parameters, the relative position between two plates has a certain effect on the welding performance.
Then, for the structural characteristics of laser Welding of auto body-in-white and the difficulties of lap welding of galvanized sheets, the influence of incident angle of laser beam, the plates space and the welding layout on the mechanical properties of the welded joint were analyzed. And the critical incident angle and the limit welding plates space in different lap joints and other effecting factors condition were studied. The results showed that plates thickness, weld width have a certain impact on the critical beam incident angle and the limit plates space. When plates thickness is large, the beam incident angle should not be too large, but the plates space may be increased appropriately. And when the weld width is narrow, the beam incident angle can be properly increased, but the plates space can't be too large. In addition, the plates space and the beam incident angle are mutually influenced. When plates space is small, the beam incident angle should not be too big. When the size of workpiece and the total length of welding seam are constant, the surface morphology and the mechanical properties of the lap joint arranged according the weld seam layout principle "short length and multi section" are good.
Finally, the performance of laser welding and resistance spot welding were compared. For the same plate's lap joint, designing different length of laser seam and through comparing the mechanical properties of weld joints with different seam length, one considerable welding seam was obtained. The influence of laser welding seam length on the mechanical properties of the lap joint was summarized. And the influence such as different thickness, different plates, different weld pool width, and relative position of heterogeneous plates and so on also were analyzed. The results showed that when the plate thickness and weld pool width are not the same, the laser weld length is different. For the lap joint of heterogeneous plates with similar thickness and material, their relative position has little impact on determining the shortest length of welding seam. In addition, based on the door parts of a vehicle, a comparison test between laser welding and resistance welding was carried out. Results found that under laser welding condition, the welding speed and the overall static stiffness of the door were higher, and the laser welding process reflected a higher flexibility. Simultaneously, results also showed that compared with the resistance spot welding joint, the microstructure of laser welding joint is more even and smaller, the hardness is higher, and the corrosion resistance is better.
引文
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