熔化极电弧焊过程数字化模拟系统
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摘要
熔化极电弧焊由于自身的优点在生产实践得到广泛的应用,焊接过程的数学模型化是实现焊接过程高水平数字化过程控制的基础。本文利用计算机仿真的方法对熔化极电弧焊过程进行了深入研究。
首先,通过对熔化极电弧焊熔滴过渡机理及其影响因素的分析,奠定了建立数字化模型的基础。其次,本文采用Matlab软件,在建立电源—电弧系统仿真模型、电弧非线性负载仿真模型和确定电弧长度仿真模型的基础上,针对熔滴过渡的不同形式分别对射流过渡、滴状过渡、短路过渡过程进行了建模,模型考虑了熔滴的长大对弧长的影响,建立了熔滴长大过程的模型,并考虑了由于噪声、焊枪的不稳定等带来的干扰对焊接过程的影响,实现了射流过渡、滴状过渡到短路过渡的自动转变,从而使模型能够更加准确和全面地反映熔化极电弧焊过程。该仿真模型以组合图形方式,直观、有效地表征了各个环节的特性。
通过数字化模型的运行,得出了各焊接参数的仿真数值和变化趋势图,对比了熔滴过渡三种形式的不同,分析了熔滴尺寸对焊接参数及其波形的影响,研究了它与熔滴过渡频率的关系,还对一些重要参数之间的相互关系进行了分析。将仿真分析得到的结果与现有的实验数据资料进行比较,结果基本相符,并且得出的结论符合理论分析和实验要求。研究结果表明:本文建立的数字化模拟系统可以准确地模拟熔化极电弧焊过程,所建立的系统是合理的并且是实用的。
Consumable Metal Arc Welding(MAW) has been widely applied because of its advantage. Mathematics modeling of welding process is the base of process control to achieve highly level digitization of welding process. In this paper, the computer simulation of MAW process is deeply studied by the method of computer simulation.
Firstly, the mechanism of metal transfer and the affecting factors is analysed, which is the base to estabilish the mathmatical model. Secondly, the Matlab software was used, based on establishing the welding power source simulation model, the arc nonlinear load simulation model and the arc length simulation model, the model of spray transfer, the globular transfer and the short circuting transfer was estabished respectively aim to the different form of metal transfer. The model of growing process of the droplet was estabilished with considering its effect on the arc length. The automatic change among spray transfer, globular transfer and short circuting transfer was achieved. The disturbance factors such as noise, the unstable of welding gun etc is considered in this paper, thus the process of MAW can be reflected more pefectly and accurately.
Running the numerical simulation model, the simulation value and variable trend graph of welding parameters are obtained. The difference of the three droplet transfer form is compared, the influence of the droplet size on the welding parameters and their wave is analysed, the relation of the droplet size to the transfer frequency is studied, besides, the correlation of several impotant parameters is analysed. The computer simulation result is generally consistent with the welding process dynamic parameters. The result of computer simulation is not only verified by experiment results, but also be accord with correlative theory analysis. The conclusion is put forward that the simulation system estabilished in this paper can simulate the process of MAW accurately, the method to estabilish the numerical simulation system is feasibly and practically.
首先,通过对熔化极电弧焊熔滴过渡机理及其影响因素的分析,奠定了建立数字化模型的基础。其次,本文采用Matlab软件,在建立电源—电弧系统仿真模型、电弧非线性负载仿真模型和确定电弧长度仿真模型的基础上,针对熔滴过渡的不同形式分别对射流过渡、滴状过渡、短路过渡过程进行了建模,模型考虑了熔滴的长大对弧长的影响,建立了熔滴长大过程的模型,并考虑了由于噪声、焊枪的不稳定等带来的干扰对焊接过程的影响,实现了射流过渡、滴状过渡到短路过渡的自动转变,从而使模型能够更加准确和全面地反映熔化极电弧焊过程。该仿真模型以组合图形方式,直观、有效地表征了各个环节的特性。
通过数字化模型的运行,得出了各焊接参数的仿真数值和变化趋势图,对比了熔滴过渡三种形式的不同,分析了熔滴尺寸对焊接参数及其波形的影响,研究了它与熔滴过渡频率的关系,还对一些重要参数之间的相互关系进行了分析。将仿真分析得到的结果与现有的实验数据资料进行比较,结果基本相符,并且得出的结论符合理论分析和实验要求。研究结果表明:本文建立的数字化模拟系统可以准确地模拟熔化极电弧焊过程,所建立的系统是合理的并且是实用的。
Consumable Metal Arc Welding(MAW) has been widely applied because of its advantage. Mathematics modeling of welding process is the base of process control to achieve highly level digitization of welding process. In this paper, the computer simulation of MAW process is deeply studied by the method of computer simulation.
Firstly, the mechanism of metal transfer and the affecting factors is analysed, which is the base to estabilish the mathmatical model. Secondly, the Matlab software was used, based on establishing the welding power source simulation model, the arc nonlinear load simulation model and the arc length simulation model, the model of spray transfer, the globular transfer and the short circuting transfer was estabished respectively aim to the different form of metal transfer. The model of growing process of the droplet was estabilished with considering its effect on the arc length. The automatic change among spray transfer, globular transfer and short circuting transfer was achieved. The disturbance factors such as noise, the unstable of welding gun etc is considered in this paper, thus the process of MAW can be reflected more pefectly and accurately.
Running the numerical simulation model, the simulation value and variable trend graph of welding parameters are obtained. The difference of the three droplet transfer form is compared, the influence of the droplet size on the welding parameters and their wave is analysed, the relation of the droplet size to the transfer frequency is studied, besides, the correlation of several impotant parameters is analysed. The computer simulation result is generally consistent with the welding process dynamic parameters. The result of computer simulation is not only verified by experiment results, but also be accord with correlative theory analysis. The conclusion is put forward that the simulation system estabilished in this paper can simulate the process of MAW accurately, the method to estabilish the numerical simulation system is feasibly and practically.
引文
1 齐瑞.欧美各国及日本的混合气体使用情况.焊接通讯.1982,(3):37-39
2 R.D.Segot,W.D.Doti.钢的焊接性.许祖泽,王征林译.机械工业出版社,1985:1-3
3 Y.S.Kim,D.M.Mceligot,T.W.Eagar.Analysis of Electrode Heat Transfer in Metal Arc Welding.Welding Journal.1991,70(1):20-31
4 李亚江,刘鹏,刘强.气体保护焊工艺及应用.化学工业出版社,2005:127-128
5 张祥武.焊接用气体在欧美的应用及生产概况.焊接技术.1986,(4):18-22
6 殷树言,张九海.气体保护焊工艺.哈尔滨工业大学出版社,1989:230-299
7 殷树言,邵清廉.CO2焊接技术及应用.哈尔滨工业大学出版社,1992:3-85
8 陈丙森.计算机辅助焊接技术.机械工业出版社,1999:168-180
9 王方,胡仕新.熔化极气体保护焊的仿真系统.焊接学报.2003,24(1):35-40
10 李伯虎,文传源.系统仿真技术新动向.计算机仿真.1996,13(3):3-5
11 K.Nogi.National project for welding simulation.Journal of the Japan Welding Society,2001,70(2):42-61
12 Amcrican Welding Society,U.S.Depart ment of Energy.Vision for Welding Industry[R],Miami,AWS,1999
13 杜乃成.计算机仿真在焊接学科中的应用.焊接技术.1999,2(1):42-43
14 赵彭生,萧波.焊接过程的自动控制(概况与趋势).焊接技术.1993,2(2):37-40
15 Y.Kovacevic,Y.M.Zhang.Vision Sensing of 3D Weld Pool Surface.Proceedings of the 4th International Conference on Trends in Welding Research,Gatlinburg,Tennessee,USA,1995:5-8
16 李鹤岐,马跃洲.微机控制可控硅焊接电源静动特性.焊接学报.2005.12(3):175-181
17 IS.Pinchuck.Stabilization of Transfer and Methods of Reducing the Spatcering of metal in CO2 welding with a Short Arc.Welding Research adroad,1982,(5):33-35
18 D.Farson.Arc Initiation in Gas Metal Arc Welding.998:315-321in Gas Metal Arc Welding Research Supplement.1998:315-321
19 M.Richardson,P.W.Bucknall,I.Stares.The influence of power source Dynamics on wire melt in grate in pulsed GMA welding.1994,Welding Journal,73(2):32-37
20 T.P.Quinn,R.B.Madigan,T.A.Siewert.An electrode extension model for gas Metal Arc Welding.Welding Journal,1994,73(10):241-248
21 J.W.Kim,S.J.Na.A study on prediction of welding current in gas metal arc welding,Part1:Modeling of welding current in response to change of tip-to-workpiece distance.Proceedings of the In stitution of Mechanical Engineerings PartB:Journal of Engineering Manufacture,1991,205(1):59-63
22 S.K.Chio,K.H.Lee,C.D.Yoo,T.S.Lee.Analysis of metal transfer through equilibrium shape of pendent drop in GMAW.Quarterly Journal of Japan Welding Society,Vol.14,No.2:243-247
23 GE.Cook,D.R.DeLapp,R.J.Barnet,et al.Modeling and control parameters for GMAW,short-circuiting transfer.Trends in Welding Research,Proceedings of the International Conference,June 1995,721-726
24 M.Ushio,W.Mao.Modeling o f the arc sensor for DC MIG/MAG welding in open arc mode-A study of the improvement of the sensitivity and the reliability of the arc sensor in GMA welding.1996,Journal of Japan Welding Society,Vo 1.14,No.1:99-107
25 T.Janez..A mathematical model for the melting rate in welding with a multiplewire electrode.Journal of Physics D:Applied Physics,1999,Vol.32:1739-1744
26 Shpigunova,SX.Shpigunov,Yu.Nn.Saraev.Mathematical simulation of heat and mass transfer in pulsed arc welding by melting electrode.Acta Metal lurgica Sinica(English Leters),2000,Vol.13,No.1:56-62
27 J.J.Lowke.Prediction of electrode propertiesm gastungsten-arc welding and gas metal arc welding(GMAW).Trans.JWRI,1996,Vol.25,No.2:1-8
28 Bottauscio Oriano,Croti Gabriella,Farina Giovanni,etal.Numerical analysis of heating transient of electric under short-circuit conditions.TFFF Transactions,Hybrids and Technology,1993,Vol.16,No.5:563-570
29 黄石生,张军红,余文松等.脉冲MIG焊动态过程的仿真.电焊机.2001,(4):16-25
30 张军红,王洪方.弧焊过程仿真研究.计算机仿真.2002,19(5):111-113
31 冯曰海,卢振洋,刘嘉等.全数字控制CO2焊Matlab/Simulink建模与仿真. 焊接学报.2005,26(7):165-167
32 王广伟,蔡燕,华学明等.气体保护焊短路过渡熔滴成形的建模分析.焊接学报.2007,27(8):73-76
33 张光先,邹增大,陈仁富等.CO2气保焊表面张力过渡的建模及仿真.焊接学报.2003(4):68-72
34 何建萍,焦馥杰,华学明等.短路过渡GMAW系统动态过程参数的研究.焊接.2006(3):21-23
35 杭争翔,刘桂秋,宋政等.CO2焊接逆变电源-电弧系统的仿真.焊接学报.2003(2):77-79
36 左敦桂,李芳,华学明等.短路过渡焊接电源系统建模及仿真研究.电焊机.2007f1):27-31
37 殷树言,耿正,刚铁.晶闸管整流弧焊机的设计与调试.机械工业出版社,1997:15-23
38 任平平.计算机仿真技术在逆变焊接电源中的应用.焊接学报.2002(5):22-23
39 杜乃成.计算机仿真在焊接学科中的应用.焊接技术,1999(2):42-43
40 Kas.Appreciation of the quality of welding transformers.WELDING IN THE WORLD,1968,6(3):162-180
41 李中友.IGBT弧焊逆变器研制中的几点体会.电焊机,1995,(4):9-15
42 刘藻珍,魏华梁.系统仿真.北京:北京理工大学出版社,1998:45-50
43 邓黎丽.AWP波控CO2短路过渡焊的计算机仿真及实验研究:硕士学位论文.2002:3-15
44 薛定宇,陈阳泉.基于MATLAB/Simulink的系统仿真技术及应用.北京:清华大学出版社,2002:6-8
45 王正林,王胜开,陈国顺.MATLAB/Simulink与控制系统仿真.电子工业出版社,2005:6-9
46 Duane Hanselman,bruce Littlefield.精通Matlab7.朱仁峰译.清华大学出版社,2006:1-3
47 殷树言.气体保护焊工艺基础.机械工业出版社,2007:88-91
48 L.C.Amson,.Analysis of the gas shielded consumable metal arc welding system British Journal,1962(41):232-249
49 J.C.Amson.Loretz force in the molten tip of an arc electrode.British Journal,1965,Vol.16:1169-1179
50 J.F.Lancaster.The Physics of Welding.2ed.,1985,Prgramon Press.70-75
51 Lord Rayleigh.Proceedings of the Mathematics Society,1997:104-108
52 C.J.Allum.Metal transfer in arc welding as varicose instability:partⅠ-varicose Instability in acurrent-carrying liquid cylinder with surface charge.Journal of PhysicsD:Applied Physics 18,1985,1431-1446
53 C.J.Allum.Metal transfer in arc welding as varicose instability:part2-Development of model for arc welding.Journal of PhysicsD:Applied Physics18,1985:1447-1468
54 YS.Kim,T.W.Eagar.Analysis of metal transfer in gas metal arc welding.Welding Journal,Nemchinsky,VA.1993,V61.72,No:269-278
55 T.M.Joo.Analysis of molten shape by energy method in GMA process.MS Thesis,Korea Advanced Institute of Science and Technology.1994.10-12
56 S.K.Chio,K.H.Lee,C.D.Yoo,T.S.Lee.Analysis of metal transfer through equilibrium shape of dpendent drop in GMAW.Quarterly Journal of Japan Welding Society,Vol.14,No.2:243- 247
57 TM.Joo,C.D.Yoo,TS.Lee.Effects of welding conditions on molten drop geometry in arc welding.Journal of Manufacturing Science and Engineering,1996,No.118:623-627
58 杨春利,林三宝.电弧焊基础.哈尔滨工业大学出版社.2003:166-170
59 李亚江,刘鹏,刘强.气体保护焊工艺及应用.化学工业出版社,2005:45
60 JH.Chio,JY.Lee,CDYoo.Simulation of dynamic behavior in a GMAW System [J].Welding Journal,2001,80(10):239-245
61 张连第.MIG焊熔化速率的研究.清华大学学报.1982,22(3):47-56
2 R.D.Segot,W.D.Doti.钢的焊接性.许祖泽,王征林译.机械工业出版社,1985:1-3
3 Y.S.Kim,D.M.Mceligot,T.W.Eagar.Analysis of Electrode Heat Transfer in Metal Arc Welding.Welding Journal.1991,70(1):20-31
4 李亚江,刘鹏,刘强.气体保护焊工艺及应用.化学工业出版社,2005:127-128
5 张祥武.焊接用气体在欧美的应用及生产概况.焊接技术.1986,(4):18-22
6 殷树言,张九海.气体保护焊工艺.哈尔滨工业大学出版社,1989:230-299
7 殷树言,邵清廉.CO2焊接技术及应用.哈尔滨工业大学出版社,1992:3-85
8 陈丙森.计算机辅助焊接技术.机械工业出版社,1999:168-180
9 王方,胡仕新.熔化极气体保护焊的仿真系统.焊接学报.2003,24(1):35-40
10 李伯虎,文传源.系统仿真技术新动向.计算机仿真.1996,13(3):3-5
11 K.Nogi.National project for welding simulation.Journal of the Japan Welding Society,2001,70(2):42-61
12 Amcrican Welding Society,U.S.Depart ment of Energy.Vision for Welding Industry[R],Miami,AWS,1999
13 杜乃成.计算机仿真在焊接学科中的应用.焊接技术.1999,2(1):42-43
14 赵彭生,萧波.焊接过程的自动控制(概况与趋势).焊接技术.1993,2(2):37-40
15 Y.Kovacevic,Y.M.Zhang.Vision Sensing of 3D Weld Pool Surface.Proceedings of the 4th International Conference on Trends in Welding Research,Gatlinburg,Tennessee,USA,1995:5-8
16 李鹤岐,马跃洲.微机控制可控硅焊接电源静动特性.焊接学报.2005.12(3):175-181
17 IS.Pinchuck.Stabilization of Transfer and Methods of Reducing the Spatcering of metal in CO2 welding with a Short Arc.Welding Research adroad,1982,(5):33-35
18 D.Farson.Arc Initiation in Gas Metal Arc Welding.998:315-321in Gas Metal Arc Welding Research Supplement.1998:315-321
19 M.Richardson,P.W.Bucknall,I.Stares.The influence of power source Dynamics on wire melt in grate in pulsed GMA welding.1994,Welding Journal,73(2):32-37
20 T.P.Quinn,R.B.Madigan,T.A.Siewert.An electrode extension model for gas Metal Arc Welding.Welding Journal,1994,73(10):241-248
21 J.W.Kim,S.J.Na.A study on prediction of welding current in gas metal arc welding,Part1:Modeling of welding current in response to change of tip-to-workpiece distance.Proceedings of the In stitution of Mechanical Engineerings PartB:Journal of Engineering Manufacture,1991,205(1):59-63
22 S.K.Chio,K.H.Lee,C.D.Yoo,T.S.Lee.Analysis of metal transfer through equilibrium shape of pendent drop in GMAW.Quarterly Journal of Japan Welding Society,Vol.14,No.2:243-247
23 GE.Cook,D.R.DeLapp,R.J.Barnet,et al.Modeling and control parameters for GMAW,short-circuiting transfer.Trends in Welding Research,Proceedings of the International Conference,June 1995,721-726
24 M.Ushio,W.Mao.Modeling o f the arc sensor for DC MIG/MAG welding in open arc mode-A study of the improvement of the sensitivity and the reliability of the arc sensor in GMA welding.1996,Journal of Japan Welding Society,Vo 1.14,No.1:99-107
25 T.Janez..A mathematical model for the melting rate in welding with a multiplewire electrode.Journal of Physics D:Applied Physics,1999,Vol.32:1739-1744
26 Shpigunova,SX.Shpigunov,Yu.Nn.Saraev.Mathematical simulation of heat and mass transfer in pulsed arc welding by melting electrode.Acta Metal lurgica Sinica(English Leters),2000,Vol.13,No.1:56-62
27 J.J.Lowke.Prediction of electrode propertiesm gastungsten-arc welding and gas metal arc welding(GMAW).Trans.JWRI,1996,Vol.25,No.2:1-8
28 Bottauscio Oriano,Croti Gabriella,Farina Giovanni,etal.Numerical analysis of heating transient of electric under short-circuit conditions.TFFF Transactions,Hybrids and Technology,1993,Vol.16,No.5:563-570
29 黄石生,张军红,余文松等.脉冲MIG焊动态过程的仿真.电焊机.2001,(4):16-25
30 张军红,王洪方.弧焊过程仿真研究.计算机仿真.2002,19(5):111-113
31 冯曰海,卢振洋,刘嘉等.全数字控制CO2焊Matlab/Simulink建模与仿真. 焊接学报.2005,26(7):165-167
32 王广伟,蔡燕,华学明等.气体保护焊短路过渡熔滴成形的建模分析.焊接学报.2007,27(8):73-76
33 张光先,邹增大,陈仁富等.CO2气保焊表面张力过渡的建模及仿真.焊接学报.2003(4):68-72
34 何建萍,焦馥杰,华学明等.短路过渡GMAW系统动态过程参数的研究.焊接.2006(3):21-23
35 杭争翔,刘桂秋,宋政等.CO2焊接逆变电源-电弧系统的仿真.焊接学报.2003(2):77-79
36 左敦桂,李芳,华学明等.短路过渡焊接电源系统建模及仿真研究.电焊机.2007f1):27-31
37 殷树言,耿正,刚铁.晶闸管整流弧焊机的设计与调试.机械工业出版社,1997:15-23
38 任平平.计算机仿真技术在逆变焊接电源中的应用.焊接学报.2002(5):22-23
39 杜乃成.计算机仿真在焊接学科中的应用.焊接技术,1999(2):42-43
40 Kas.Appreciation of the quality of welding transformers.WELDING IN THE WORLD,1968,6(3):162-180
41 李中友.IGBT弧焊逆变器研制中的几点体会.电焊机,1995,(4):9-15
42 刘藻珍,魏华梁.系统仿真.北京:北京理工大学出版社,1998:45-50
43 邓黎丽.AWP波控CO2短路过渡焊的计算机仿真及实验研究:硕士学位论文.2002:3-15
44 薛定宇,陈阳泉.基于MATLAB/Simulink的系统仿真技术及应用.北京:清华大学出版社,2002:6-8
45 王正林,王胜开,陈国顺.MATLAB/Simulink与控制系统仿真.电子工业出版社,2005:6-9
46 Duane Hanselman,bruce Littlefield.精通Matlab7.朱仁峰译.清华大学出版社,2006:1-3
47 殷树言.气体保护焊工艺基础.机械工业出版社,2007:88-91
48 L.C.Amson,.Analysis of the gas shielded consumable metal arc welding system British Journal,1962(41):232-249
49 J.C.Amson.Loretz force in the molten tip of an arc electrode.British Journal,1965,Vol.16:1169-1179
50 J.F.Lancaster.The Physics of Welding.2ed.,1985,Prgramon Press.70-75
51 Lord Rayleigh.Proceedings of the Mathematics Society,1997:104-108
52 C.J.Allum.Metal transfer in arc welding as varicose instability:partⅠ-varicose Instability in acurrent-carrying liquid cylinder with surface charge.Journal of PhysicsD:Applied Physics 18,1985,1431-1446
53 C.J.Allum.Metal transfer in arc welding as varicose instability:part2-Development of model for arc welding.Journal of PhysicsD:Applied Physics18,1985:1447-1468
54 YS.Kim,T.W.Eagar.Analysis of metal transfer in gas metal arc welding.Welding Journal,Nemchinsky,VA.1993,V61.72,No:269-278
55 T.M.Joo.Analysis of molten shape by energy method in GMA process.MS Thesis,Korea Advanced Institute of Science and Technology.1994.10-12
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