高速GMAW驼峰焊道形成机理的研究
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摘要
高速GMAW作为一种高效电弧焊焊接工艺,因其设备成本低、操作简单、适应性强、焊接生产率高,具有广泛的应用前景。但大幅度提高焊接速度时,会产生咬边、驼峰等焊道成形缺陷,严重制约着该工艺在实际生产中的应用。为抑制驼峰焊道,近年来针对驼峰缺陷形成机理开展了一些研究,取得了一定进展。但是,仍存在很多问题需要进一步深入研究和解决,主要表现在:(1)对驼峰焊道形成机理的研究大部分仍处于定性描述阶段,缺乏系统的、理论的解释和定量描述;(2)有关驼峰焊道的数学模型还不能反映高速焊接过程的实质;(3)缺乏对高速焊熔池三维形貌及温度场动态变化情况的定量分析。因此,建立反映高速GMAW焊接工艺特点的数学模型,定量描述和分析驼峰焊道的形成机理及其主要影响因素,对于抑制驼峰焊道的产生、研发高速GMAW焊接工艺与设备、并推广和应用高速GMAW焊接工艺,都具有重要的理论意义和工程实用价值。
本文建立了高速GMAW焊接熔池瞬时热物理行为的数值分析模型。根据高速GMAW焊接熔池细长和表面变形严重的实际情况,采用贴体坐标系来处理复杂的物理边界,推导相应的离散化控制方程组,利用附加热源法处理能量边界条件。为减小数值传递造成的误差、提高计算速度,采用二次抛物线插值法传递非均匀动态网格中前后时刻的表面变形值和温度值。采用模块化结构设计,增强程序的可读性和可维护性。
针对高速GMAW焊接过程的主要特点之一,考虑熔池后向液体流对熔池表面变形的影响,推导出含有后向液体流动能项的熔池表面变形方程。在估算出熔池最大流速的基础上,对熔池内流体速度分布做适当的简化描述,构造恰当的流速分布函数。计算结果表明,动能较大的后向液体流极大地改变了熔池受力情况,导致熔池尾部出现液体堆积和熔池中部出现液态薄层,而这两者又是导致驼峰焊道形成的关键因素。
基于高速GMAW焊接过程的另一主要特点,考察不同熔滴热焓分布模式对驼峰焊道形成的影响程度。提出了较为符合高速GMAW焊接过程特点的熔滴热焓分布模式,即,在熔池前部凹陷区,熔滴热焓分布在熔池底部液体薄层内;在熔池尾部,熔滴热焓平均分布在整个液体堆积层内。计算结果表明,该分布模式能够反映驼峰焊道形成过程中熔池动态变化的特点及其规律。
利用所建立的模型,对高速GMAW驼峰焊道形成的完整过程(包括形成表面变形严重的熔池、熔池长大(伴随驼峰隆起)、熔池中部液态薄层提前凝固、尾部液态金属逐渐凝固四个过程)进行数值模拟。通过数值计算发现,熔池中部液态薄层得不到足够的热能(包括熔滴热焓和电弧热)是其先于尾部液态金属凝固的主要原因;而此处液态薄层率先凝固意味着一个驼峰即将形成、同时另一驼峰开始孕育的周期过程。得出了不同焊接工艺参数下的工件上表面、纵截面(y=0)温度场以及焊道三维形状的瞬时演变过程,定量分析了驼峰焊道的形成过程以及焊接工艺参数的影响。
开展了高速GMAW焊接工艺实验,数值计算结果与实验值基本吻合,所建模型能够反映高速GMAW焊接过程的主要特点及规律。基于数值分析结果,提出了抑制驼峰焊道的工艺措施,经实验证明效果明显。
The high-speed gas metal arc welding (GMAW) has great potential in application because of its low cost, easiness to use and high productivity. However, high welding speed usually brings some unusual problems, such as undercutting, humping, which seriously restrict its application in practical manufacture. In order to prevent the humping defects, many efforts have been done to investigate the mechanism of humping formation in recent years, and great progresses have been made. But many problems still exist, for example: (1) Humping formation mechanism is still analyzed qualitatively, lack of quantitative explanation. (2) Many mathematical models can not reflect the essential process of high-speed welding quantificationally because they are based on the oversimplification of the weld pool shape. (3) The study of three-dimensional geometry of weld pool and dynamic temperature fileds for humping bead is rare. Thus, based on characters of high-speed GMAW process, mathematical models are needed to be further developed to describe the humping formation mechanism quantificationally. This is of great theoretical and practical significances for optimizing welding parameters and popularizing high-speed GMAW.
The mathematical models are developed to investigate the dynamic physical behaviors during high-speed GMAW. Considering the serious surface deformation and long shape of weld pool, body-fitted coordinate is used to deal with complex physical boundaries, and the governing equations are discretized by this method. The additional source term method is employed to solve energy boundary conditions. To reduce error evoked by data transfer and improve calculation efficiency, parabola interpolation method is adopted to inherit former data in non-uniform dynamic grids. Modular structure is adopted to improve the readability and maintainability of programs.
A new surface deformation equation is deduced by considering influence of backward flowing liquid which is one of the major characters during high-speed GMAW. After simply calculating the maximum liquid velocity, an appropriate distribution of liquid speed is proposed based on experimental observation to simplify simulation process. The results show that this backward liquid obviously changes the force acting on weld pool, which causes metal accumulated at rear of weld pool and the thinner liquid layer occurred in the middle of weld pool. Moreover, this metal accumulation and thinner liquid layer are the key factors contributing to humping bead.
Based on another major character of high-speed GMAW, different modes for droplet heat content distribution are compared and studied. Finally, an appropriate mode is proposed as follows, droplet heat content is distributed in bottom layer of gouging region, and is averagely distributed in the whole layer at rear of weld pool. The results show that this mode can reflect the forming and evolving of weld pool in high-speed GMAW.
By using the developed models, the whole process of humping bead formation(including forming serious deformed weld pool, weld pool and humping growth, thinner layer early solidification, accumulated metal solidification) is numerical simulated. It is found that lack of droplet heat and arc heat in the middle of pool is the major reason for early solidification for thinner layer. And early solidification also means that a humping will be formed and a new humping will be gestated. It is a periodic process. The temperatures fileds on top surface and in longitudinal section of workpiece, transient growth of 3-D shape of weld bead are obtained under different welding parameters to quantificationally analyses humping bead formation process and the influence of welding parameters.
Experiments are carried out, and the predicted results are in good agreement with measured data. It means that those models developed above can reflect major characters of high-speed GMAW. Based on numerical analysis, the methods of restraining humping bead are proposed, and the experimental results show they work well.
本文建立了高速GMAW焊接熔池瞬时热物理行为的数值分析模型。根据高速GMAW焊接熔池细长和表面变形严重的实际情况,采用贴体坐标系来处理复杂的物理边界,推导相应的离散化控制方程组,利用附加热源法处理能量边界条件。为减小数值传递造成的误差、提高计算速度,采用二次抛物线插值法传递非均匀动态网格中前后时刻的表面变形值和温度值。采用模块化结构设计,增强程序的可读性和可维护性。
针对高速GMAW焊接过程的主要特点之一,考虑熔池后向液体流对熔池表面变形的影响,推导出含有后向液体流动能项的熔池表面变形方程。在估算出熔池最大流速的基础上,对熔池内流体速度分布做适当的简化描述,构造恰当的流速分布函数。计算结果表明,动能较大的后向液体流极大地改变了熔池受力情况,导致熔池尾部出现液体堆积和熔池中部出现液态薄层,而这两者又是导致驼峰焊道形成的关键因素。
基于高速GMAW焊接过程的另一主要特点,考察不同熔滴热焓分布模式对驼峰焊道形成的影响程度。提出了较为符合高速GMAW焊接过程特点的熔滴热焓分布模式,即,在熔池前部凹陷区,熔滴热焓分布在熔池底部液体薄层内;在熔池尾部,熔滴热焓平均分布在整个液体堆积层内。计算结果表明,该分布模式能够反映驼峰焊道形成过程中熔池动态变化的特点及其规律。
利用所建立的模型,对高速GMAW驼峰焊道形成的完整过程(包括形成表面变形严重的熔池、熔池长大(伴随驼峰隆起)、熔池中部液态薄层提前凝固、尾部液态金属逐渐凝固四个过程)进行数值模拟。通过数值计算发现,熔池中部液态薄层得不到足够的热能(包括熔滴热焓和电弧热)是其先于尾部液态金属凝固的主要原因;而此处液态薄层率先凝固意味着一个驼峰即将形成、同时另一驼峰开始孕育的周期过程。得出了不同焊接工艺参数下的工件上表面、纵截面(y=0)温度场以及焊道三维形状的瞬时演变过程,定量分析了驼峰焊道的形成过程以及焊接工艺参数的影响。
开展了高速GMAW焊接工艺实验,数值计算结果与实验值基本吻合,所建模型能够反映高速GMAW焊接过程的主要特点及规律。基于数值分析结果,提出了抑制驼峰焊道的工艺措施,经实验证明效果明显。
The high-speed gas metal arc welding (GMAW) has great potential in application because of its low cost, easiness to use and high productivity. However, high welding speed usually brings some unusual problems, such as undercutting, humping, which seriously restrict its application in practical manufacture. In order to prevent the humping defects, many efforts have been done to investigate the mechanism of humping formation in recent years, and great progresses have been made. But many problems still exist, for example: (1) Humping formation mechanism is still analyzed qualitatively, lack of quantitative explanation. (2) Many mathematical models can not reflect the essential process of high-speed welding quantificationally because they are based on the oversimplification of the weld pool shape. (3) The study of three-dimensional geometry of weld pool and dynamic temperature fileds for humping bead is rare. Thus, based on characters of high-speed GMAW process, mathematical models are needed to be further developed to describe the humping formation mechanism quantificationally. This is of great theoretical and practical significances for optimizing welding parameters and popularizing high-speed GMAW.
The mathematical models are developed to investigate the dynamic physical behaviors during high-speed GMAW. Considering the serious surface deformation and long shape of weld pool, body-fitted coordinate is used to deal with complex physical boundaries, and the governing equations are discretized by this method. The additional source term method is employed to solve energy boundary conditions. To reduce error evoked by data transfer and improve calculation efficiency, parabola interpolation method is adopted to inherit former data in non-uniform dynamic grids. Modular structure is adopted to improve the readability and maintainability of programs.
A new surface deformation equation is deduced by considering influence of backward flowing liquid which is one of the major characters during high-speed GMAW. After simply calculating the maximum liquid velocity, an appropriate distribution of liquid speed is proposed based on experimental observation to simplify simulation process. The results show that this backward liquid obviously changes the force acting on weld pool, which causes metal accumulated at rear of weld pool and the thinner liquid layer occurred in the middle of weld pool. Moreover, this metal accumulation and thinner liquid layer are the key factors contributing to humping bead.
Based on another major character of high-speed GMAW, different modes for droplet heat content distribution are compared and studied. Finally, an appropriate mode is proposed as follows, droplet heat content is distributed in bottom layer of gouging region, and is averagely distributed in the whole layer at rear of weld pool. The results show that this mode can reflect the forming and evolving of weld pool in high-speed GMAW.
By using the developed models, the whole process of humping bead formation(including forming serious deformed weld pool, weld pool and humping growth, thinner layer early solidification, accumulated metal solidification) is numerical simulated. It is found that lack of droplet heat and arc heat in the middle of pool is the major reason for early solidification for thinner layer. And early solidification also means that a humping will be formed and a new humping will be gestated. It is a periodic process. The temperatures fileds on top surface and in longitudinal section of workpiece, transient growth of 3-D shape of weld bead are obtained under different welding parameters to quantificationally analyses humping bead formation process and the influence of welding parameters.
Experiments are carried out, and the predicted results are in good agreement with measured data. It means that those models developed above can reflect major characters of high-speed GMAW. Based on numerical analysis, the methods of restraining humping bead are proposed, and the experimental results show they work well.
引文
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