铝合金组件钎焊变形及应力有限元分析
|
摘要
3A21是具有塑性高、加工性好,良好的抗蚀性及焊接性的铝合金,作为一种结构材料在当今航空航天领域中的应用越来越广泛,在实际应用中往往需要采用焊接方法使之成为特定形状的构件,对于形状尺寸精度要求很高而接头强度要求次之的构件,采用钎焊方法比较合适。由于在钎焊过程中,钎料与母材之间的力学性能、热物理性能的差别,特别是线膨胀系数的差别,因此在焊接过程中会在焊接接头附近产生较大的热应力,引起焊接构件的变形,这会影响结构件的尺寸精度,导致结构件的加工失效,浪费原材料增加生产成本。因此分析结构件钎焊后的残余应力对结构设计和工艺参数优化,以便获得可靠的钎焊结构具有一定的指导意义。
本论文通过采用Marc非线性有限元软件,采用热弹塑性有限元方法,在考虑了材料性能参数随温度变化的情况下,对铝合金钎焊接头在钎焊后的变形及应力分布进行了分析。并在此基础上,对铝合金箱体结构在钎焊过程中的箱体整体变形及应力分布进行了分析,并用三维坐标移对箱体的变形进行了测量以验证模拟的可靠性。优化箱体钎焊的夹持状态,并计算优化工艺条件下的箱体变形及应力分布情况。
模拟结果表明:铝合金钎焊接头在钎焊后产生的y向应力和z向应力对接头的强度影响较大;在接头中上铝板与钎料接触面处达到最大值为164Mpa的残余应力。钎缝厚度为1mm左右时焊后残余应力值最小,在铝合金接头上施加一定的y向压力,可以有效的降低焊后残余应力。模拟原有夹持工艺条件下箱体整体钎焊结果表明:箱体的最大变形出现在箱体背板上,最大变形量为11.49mm;箱体的上板上边缘在y方向上的变形范围为0～1.375mm,上铝板中线在y方向上的变形范围为2.128～4.245mm。箱体的最大残余应力出现在箱体背板根部边缘,其最大残余应力为155.8MPa。模拟优化工艺条件下箱体整体钎焊结果表明:箱体的整体变形量减小,背板处的最大变形量为1.25mm,上板中线在在y方向的变形范围为1.180～1.958mm。箱体的残余应力有所降低,在背板根部边缘的最大残余应力为140.1 MPa。
The 3A21 aluminum alloy has the perfect properties of plasticity, easy processing ,corrosion resistantance and better weldability,which has been popular used in aero space. But it need specific shape by means of welding craft in practice and need high precision than the toughness, so braze welding became the fit technology. Because it showed difference between the solder and base metal of the mechanical properties, thermal physical properties ,especailly the liner inflation in braze welding, so there may appear high thermal stress in the welding joints which induced deformation and influenced the precision of size ,then caused the failure of the structure and increased the cost. So analysis of the residual stress of welded structure taken the predominant place for structure design and craft.
The highly nonlinear finite element analysis software MSC.Marc and thermal elastoplasticity method were adopted to analyse the distribution and change of stress in braze welding, with in consideration of the materials properties parameter transmutability with the change of temperature. A conception based on the front supposition, analysed the stress distribution and whole deformation of the box in braze welding, and surveyed the box deformation and certified the reliability through the use of three-dimensional coordinate.Optimized the clamp condition, then computated the box deformation and stress distribution in poptimized condition.
The result showed that, the residual stress in Y direction and Z direction had a great influence on the toughness of the braze welding joints. There occurred the greatest residual stress of 164Mpa onto the contact area between the aluminum and solder. The residual stress was the smallest when the welded seam is 1mm, and it may reduce the residual stress effectively when exerted press in Y direction on the welding joints.The simulation result of the original clamp craft showed that, the greatest deformation was occurred in back of the box which was 11.49mm. the deformation range in Y direction of upside edge of aluminum box was 0～1.375mm, the deformation range in Y direction of upside median line of aluminum box was 2.128～4.245mm. The greatest residual stress was occurred in root edge of the box back and the residual stress was 155.8Mpa. The simulation result of the optimized craft showed that, the whole deformation of the box decreased, the greatest deformation was 1.25mm and the deformation range in Y direction of upside median line of aluminum box was 1.180～1.958mm. The residual stress of the box decreased ,the greatest residual stress in root edge of the box back and the residual stress was140.1 Mpa.
本论文通过采用Marc非线性有限元软件,采用热弹塑性有限元方法,在考虑了材料性能参数随温度变化的情况下,对铝合金钎焊接头在钎焊后的变形及应力分布进行了分析。并在此基础上,对铝合金箱体结构在钎焊过程中的箱体整体变形及应力分布进行了分析,并用三维坐标移对箱体的变形进行了测量以验证模拟的可靠性。优化箱体钎焊的夹持状态,并计算优化工艺条件下的箱体变形及应力分布情况。
模拟结果表明:铝合金钎焊接头在钎焊后产生的y向应力和z向应力对接头的强度影响较大;在接头中上铝板与钎料接触面处达到最大值为164Mpa的残余应力。钎缝厚度为1mm左右时焊后残余应力值最小,在铝合金接头上施加一定的y向压力,可以有效的降低焊后残余应力。模拟原有夹持工艺条件下箱体整体钎焊结果表明:箱体的最大变形出现在箱体背板上,最大变形量为11.49mm;箱体的上板上边缘在y方向上的变形范围为0～1.375mm,上铝板中线在y方向上的变形范围为2.128～4.245mm。箱体的最大残余应力出现在箱体背板根部边缘,其最大残余应力为155.8MPa。模拟优化工艺条件下箱体整体钎焊结果表明:箱体的整体变形量减小,背板处的最大变形量为1.25mm,上板中线在在y方向的变形范围为1.180～1.958mm。箱体的残余应力有所降低,在背板根部边缘的最大残余应力为140.1 MPa。
The 3A21 aluminum alloy has the perfect properties of plasticity, easy processing ,corrosion resistantance and better weldability,which has been popular used in aero space. But it need specific shape by means of welding craft in practice and need high precision than the toughness, so braze welding became the fit technology. Because it showed difference between the solder and base metal of the mechanical properties, thermal physical properties ,especailly the liner inflation in braze welding, so there may appear high thermal stress in the welding joints which induced deformation and influenced the precision of size ,then caused the failure of the structure and increased the cost. So analysis of the residual stress of welded structure taken the predominant place for structure design and craft.
The highly nonlinear finite element analysis software MSC.Marc and thermal elastoplasticity method were adopted to analyse the distribution and change of stress in braze welding, with in consideration of the materials properties parameter transmutability with the change of temperature. A conception based on the front supposition, analysed the stress distribution and whole deformation of the box in braze welding, and surveyed the box deformation and certified the reliability through the use of three-dimensional coordinate.Optimized the clamp condition, then computated the box deformation and stress distribution in poptimized condition.
The result showed that, the residual stress in Y direction and Z direction had a great influence on the toughness of the braze welding joints. There occurred the greatest residual stress of 164Mpa onto the contact area between the aluminum and solder. The residual stress was the smallest when the welded seam is 1mm, and it may reduce the residual stress effectively when exerted press in Y direction on the welding joints.The simulation result of the original clamp craft showed that, the greatest deformation was occurred in back of the box which was 11.49mm. the deformation range in Y direction of upside edge of aluminum box was 0～1.375mm, the deformation range in Y direction of upside median line of aluminum box was 2.128～4.245mm. The greatest residual stress was occurred in root edge of the box back and the residual stress was 155.8Mpa. The simulation result of the optimized craft showed that, the whole deformation of the box decreased, the greatest deformation was 1.25mm and the deformation range in Y direction of upside median line of aluminum box was 1.180～1.958mm. The residual stress of the box decreased ,the greatest residual stress in root edge of the box back and the residual stress was140.1 Mpa.
引文
1 张启运,庄红寿主编.《钎焊手册》.北京:机械工业出版社,1999:27
2 王祝堂,田荣璋.铝合金及其加工手册.长沙:中南大学出版社,2000
3 Matsumoto Jiro,Kobayashi Masao,Hotta Motoshi.Weld abilities of 2017,2024 and 2219 allloys.Jounnal of Light Metal Welding and Construction.1985(23)12:529-550
4 邱惠中.先进钎焊技术在航天器上的应用.宇航材料工艺.2000(3):17-20
5 王钰.铝合金在造船中的应用与发展.轻金属,1994:(4),49-54
6 张典文.21世纪SMT发展趋势和对策.电子工艺技术,2001(1):1-9
7 中国机械工程学会焊接学会.焊接手册.焊接方法及设备:第1卷.北京:机械工业出版社,2001:543-546
8 印有胜.钎焊手册.哈尔滨:黑龙江科技技术出版社出版。1989:2
9 张启运,庄红寿主编.《钎焊手册》,第一版.北京:机械工业出版社.1999:1
10 胡刚,康慧.铝合金真空钎焊的发展[J].焊接技术,2001,(33):1-3
11 Palriclc E P.Vacuum brazing of aluminum[J].Welding Journal,March,1975:159-169
12 陈丙森.计算机辅助焊接技术[M].北京:机械工业出版,1999
13 汪建华.焊接数值模拟技术及其应用.上海:上海交通大学出版社,2003
14 李开泰,黄艾香,杨庆怀.有限元方法及其应用.西安:西安交通大学出版社.2002
15 Y Nagasaka.Mathematical Model of Phase Transformation and Elasto-Plastic Stress in the Water Spray Quenching of Steel Bars.Metallurgical Transaction[A].1993,24:795-808
16 F.Fernandes,S.Denis,A.Sitnon.Mathematical Model Coupling Phase Transformation and Temperature Evolution during Quenching of Steel Materials Science and Technology 2005,(1):839-856
17 宋天霞.非线性结构有限元分析计算.华中理工大学出版社。1996:2-6
18 R I Karlsson,B L Josefson.Three-dimensional finite element analysis of temperatures and stresses in a single-pass butt-welded pipe[J].Journal of pressure vessel technology.2004,112:76-84
19 E.F.Rybicki,D.W.Schmueser,R.W.Stonesifer,et al.A Finite Element Model for Residual Stresses and Deflections in Girth-butt Welded Pipes.Journal of Pressure Vessel Technology,Transaction ofASME.2003,100(8):256-262
20 K.Masubuchi.Prediction and Control of Residual Stresses and Distortion in Welded Structures Proceeding.Theoretical Prediction in Joining and Welding.Osaka,Japan,2000:71-88
21 Kadsson L.Thermal Stresses in Welding,in R.Hetnarski(ed.).Thermal Stresses I,North-Holland,Amsterdam,Chapter5,2001:299-389
22 Kadsson C T.Finite Element Analysis of Temperature and Stress in a Single-pass Butt-welded Pipe-influence of Mesh Density and Material Modeling.Eng.Compt,2002(6):133-141
23 熊柏青,楚建新.残余应力对Si3N4/金属钎焊接头性能的影响.中国有色金属学报,1998,8(2):210-213
24 S.B.Brown,H Song.Finite element simulation of welding of large structures.Journal of engineering for industry[J].1992,114:441-451
25 黄哲赞,项明,梁智.真空电子束钎焊温度场模拟.宇航材料工艺.2004,6:53-57
26 陈芙蓉,霍立兴,张玉凤.BT20钛合金电子束焊接残余应力三维有限元数值模拟.焊接学报.2004,25:61-70
27 程大勇,陆善义,郭义.陶瓷/金属钎焊接头内残余应力计算.材料研究学报.2000,14:49-52
28 常星,郝兆星。降低陶瓷-金属针焊残余应力的方法.沈阳建筑工程学院学报.1998,14(2):183-186
29 吴言高,李午申,邹宏军,等。焊接数值模拟技术发展现状[J].焊接学报,2002,23(2):89-92
30 张宝生.高度非线性有限元分析软件Marc及在接触分析中的应用.应用科技,2001(12):36-38
31 陈火红.MARC有限元实现实例分析教程.机械工业出版社.2003:3-15
32 范慕辉,李松年.热弹塑性应力分析的有限元方法.河北工学院学报.1995,24(4):51-58
33 王助成,邵敏.有限元法基本原理和数值方法.清华大学出版社.1997,3:483-530
34 Berry H Rabin Richard L Williamson.Hugh A Bruck,Residual Strains in A1203-Ni Joint Bonded with a Composite Interlayer Experiments and FEM Analysis.Jam Ceram Soc 1998,81(6):1541-1549
35 Henshall G A et al.Finite Element Analysis of Interlayer Welds Loaded in Tension.Welding Journal,1990,69(9):337-345
36 方昆凡主编.工程材料手册.北京:北京出版社,2002:48-54
2 王祝堂,田荣璋.铝合金及其加工手册.长沙:中南大学出版社,2000
3 Matsumoto Jiro,Kobayashi Masao,Hotta Motoshi.Weld abilities of 2017,2024 and 2219 allloys.Jounnal of Light Metal Welding and Construction.1985(23)12:529-550
4 邱惠中.先进钎焊技术在航天器上的应用.宇航材料工艺.2000(3):17-20
5 王钰.铝合金在造船中的应用与发展.轻金属,1994:(4),49-54
6 张典文.21世纪SMT发展趋势和对策.电子工艺技术,2001(1):1-9
7 中国机械工程学会焊接学会.焊接手册.焊接方法及设备:第1卷.北京:机械工业出版社,2001:543-546
8 印有胜.钎焊手册.哈尔滨:黑龙江科技技术出版社出版。1989:2
9 张启运,庄红寿主编.《钎焊手册》,第一版.北京:机械工业出版社.1999:1
10 胡刚,康慧.铝合金真空钎焊的发展[J].焊接技术,2001,(33):1-3
11 Palriclc E P.Vacuum brazing of aluminum[J].Welding Journal,March,1975:159-169
12 陈丙森.计算机辅助焊接技术[M].北京:机械工业出版,1999
13 汪建华.焊接数值模拟技术及其应用.上海:上海交通大学出版社,2003
14 李开泰,黄艾香,杨庆怀.有限元方法及其应用.西安:西安交通大学出版社.2002
15 Y Nagasaka.Mathematical Model of Phase Transformation and Elasto-Plastic Stress in the Water Spray Quenching of Steel Bars.Metallurgical Transaction[A].1993,24:795-808
16 F.Fernandes,S.Denis,A.Sitnon.Mathematical Model Coupling Phase Transformation and Temperature Evolution during Quenching of Steel Materials Science and Technology 2005,(1):839-856
17 宋天霞.非线性结构有限元分析计算.华中理工大学出版社。1996:2-6
18 R I Karlsson,B L Josefson.Three-dimensional finite element analysis of temperatures and stresses in a single-pass butt-welded pipe[J].Journal of pressure vessel technology.2004,112:76-84
19 E.F.Rybicki,D.W.Schmueser,R.W.Stonesifer,et al.A Finite Element Model for Residual Stresses and Deflections in Girth-butt Welded Pipes.Journal of Pressure Vessel Technology,Transaction ofASME.2003,100(8):256-262
20 K.Masubuchi.Prediction and Control of Residual Stresses and Distortion in Welded Structures Proceeding.Theoretical Prediction in Joining and Welding.Osaka,Japan,2000:71-88
21 Kadsson L.Thermal Stresses in Welding,in R.Hetnarski(ed.).Thermal Stresses I,North-Holland,Amsterdam,Chapter5,2001:299-389
22 Kadsson C T.Finite Element Analysis of Temperature and Stress in a Single-pass Butt-welded Pipe-influence of Mesh Density and Material Modeling.Eng.Compt,2002(6):133-141
23 熊柏青,楚建新.残余应力对Si3N4/金属钎焊接头性能的影响.中国有色金属学报,1998,8(2):210-213
24 S.B.Brown,H Song.Finite element simulation of welding of large structures.Journal of engineering for industry[J].1992,114:441-451
25 黄哲赞,项明,梁智.真空电子束钎焊温度场模拟.宇航材料工艺.2004,6:53-57
26 陈芙蓉,霍立兴,张玉凤.BT20钛合金电子束焊接残余应力三维有限元数值模拟.焊接学报.2004,25:61-70
27 程大勇,陆善义,郭义.陶瓷/金属钎焊接头内残余应力计算.材料研究学报.2000,14:49-52
28 常星,郝兆星。降低陶瓷-金属针焊残余应力的方法.沈阳建筑工程学院学报.1998,14(2):183-186
29 吴言高,李午申,邹宏军,等。焊接数值模拟技术发展现状[J].焊接学报,2002,23(2):89-92
30 张宝生.高度非线性有限元分析软件Marc及在接触分析中的应用.应用科技,2001(12):36-38
31 陈火红.MARC有限元实现实例分析教程.机械工业出版社.2003:3-15
32 范慕辉,李松年.热弹塑性应力分析的有限元方法.河北工学院学报.1995,24(4):51-58
33 王助成,邵敏.有限元法基本原理和数值方法.清华大学出版社.1997,3:483-530
34 Berry H Rabin Richard L Williamson.Hugh A Bruck,Residual Strains in A1203-Ni Joint Bonded with a Composite Interlayer Experiments and FEM Analysis.Jam Ceram Soc 1998,81(6):1541-1549
35 Henshall G A et al.Finite Element Analysis of Interlayer Welds Loaded in Tension.Welding Journal,1990,69(9):337-345
36 方昆凡主编.工程材料手册.北京:北京出版社,2002:48-54