搅拌摩擦焊接材料流动模型及在缺陷预测中的应用
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摘要
为了研究搅拌头倾角对搅拌摩擦焊接过程的影响机理,基于DEFORM-3D软件建立了带倾角的FSW三维热-力耦合模型,模拟了搅拌摩擦焊接过程中焊缝区材料的三维运动轨迹,对比分析了有无倾角时FSW过程中材料流动行为的差异.结果表明,前进侧材料绕搅拌针旋转后大部分沉积于搅拌头后方前进侧区域,返回侧的材料大部分被搅拌头旋推至后方而沉积;采用倾角可以增强搅拌头后方材料从返回侧运动至前进侧区间的流动性,同时还有利于增强材料在厚度方向的运动能力.根据模拟的材料流动行为对接头缺陷进行了趋势预测,预测结果与试验结果吻合良好.
In order to research the mechanism influenced by the tilt angle of tool pin during friction stir welding,the thermal-mechanical coupled model considering the tilt angle was established based on DEFORM-3D software.The three-dimensional material flow in the welding seam region was simulated,and the difference of the material flow behavior influenced by tool tilt angle of 0° and 2° was compared and analyzed.The results showed that most of the materials in the front advancing side deposited in the region of rear advancing side after rotating around the tool pin,while most of the materials in the front retreating side were pushed by the tool pin and deposited in the rear region.It was observed that the tilt of tool pin increased the fluidity of the material between the rear retreating side and the rear advancing side,meanwhile,the flowing behavior in the thickness was increased accordingly.The simulation results of the joint morphology agreed well with the corresponding experimental results,which illustrated that the numerical model of the material flow considering the tool tilt angle can be used for predicting the tendency of welding joint defect.
In order to research the mechanism influenced by the tilt angle of tool pin during friction stir welding,the thermal-mechanical coupled model considering the tilt angle was established based on DEFORM-3D software.The three-dimensional material flow in the welding seam region was simulated,and the difference of the material flow behavior influenced by tool tilt angle of 0° and 2° was compared and analyzed.The results showed that most of the materials in the front advancing side deposited in the region of rear advancing side after rotating around the tool pin,while most of the materials in the front retreating side were pushed by the tool pin and deposited in the rear region.It was observed that the tilt of tool pin increased the fluidity of the material between the rear retreating side and the rear advancing side,meanwhile,the flowing behavior in the thickness was increased accordingly.The simulation results of the joint morphology agreed well with the corresponding experimental results,which illustrated that the numerical model of the material flow considering the tool tilt angle can be used for predicting the tendency of welding joint defect.
引文
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[10]严铿,曹亮,陈华斌.搅拌头倾角对FSW成形和接头力学性能的影响[J].焊接学报,2005,26(12):35-38.Yan Keng,Cao Liang,Chen Huabin.Effect of tool tilt angle on formation and mechanical property of FSW[J].Transactions of the China Welding Institution,2005,26(12):35-38.
[11]Jain R,Pal S K,Singh S B.A study on the variation of forces and temperature in a friction stir welding process:a finite element approach[J].Journal of Manufacturing Process,2016,23:278-286.
[12]Khandkar M Z H,Khan J A,Reynolds A P.Prediction of temperature distribution and thermal history during friction stir welding:input torque based model[J].Science and Technology of Welding and Joining,2003,8(3):165-174.
[13]Tello K E,Gerlich A P,Mendez P F.Constants for hot deformation constitutive models for recent experimental data[J].Science and Technology of Welding and Joining,2010,15(3):260-266.
[14]Sellars C M,Tegart W J.On the mechanism of hot deformation[J].Acta Metallurgica et Materialia,1966,14(9):1136-1139.
[15]Frigaard O,Grong O,Midling O T.A process model for friction stir welding of age hardening aluminum alloys[J].Metallurgical and Materials Transactions A,2001,32(5):1189-1200.
[16]王细波.铝合金搅拌摩擦焊完全热-力耦合模拟及流动行为研究[D].北京:清华大学,2010.
[17]Zhu Y C,Chen G Q,Qing Y S.Simulation of material plastic flow driven by non-uniform friction force during friction stir welding and related defect prediction[J].Material and Design,2016,108:400-410.
[2]赵衍华,林三宝,吴林.2014铝合金搅拌摩擦焊接过程塑性金属流变可视化[J].焊接学报,2005,26(6):73-75.Zhao Yanhua,Lin Sanbao,Wu Lin.Visualization of the plastic material flow in friction stir welding of 2024 aluminum alloy[J].Transactions of the China Welding Institution,2005,26(6):73-75.
[3]陈高强,史清宇.搅拌摩擦焊接中材料流动行为数值模拟的研究进展[J].机械工程学报,2015,51(22):11-21.Chen Gaoqiang,Shi Qingyu.Recent advances in numerical simulation of material flow behavior during friction stir welding[J].Journal of Mechanical Engineering,2015,51(22):11-21.
[4]柯黎明,邢丽,黄奉安.搅拌摩擦焊接头形成过程的二维观察与分析[J].焊接学报,2005,26(3):1-4.Ke Liming,Xing Li,Huang Fengan.Two dimensional flow of plasticized materials in friction stir welded joints[J].Transactions of the China Welding Institution,2005,26(3):1-4.
[5]张昭,刘亚丽,陈金涛,等.搅拌摩擦焊接过程中材料流动形式[J].焊接学报,2007,28(11):17-21.Zhang Zhao,Liu Yali,Chen Jintao,et al.The material flow in friction stir welding[J].Transactions of the China Welding Institution,2007,28(11):17-21.
[6]Colegrove P A,Shercliff,H R.3-dimensional CFD modeling of flow round a threaded friction stir welding tool profile[J].Journal of Materials Processing Technology,2005,169(2):320-327.
[7]Schmidt H,Hattel J.A local model for the thermomechanical conditions in friction stir welding[J].Modeling and Simulation in Materials Science and Engineering,2005,13(1):77-93.
[8]Zhang H W,Zhang Z,Chen J T.3D modeling of material flow in friction stir welding under different process parameters[J].Journal of Materials Processing Technology,2007,183(1):62-70.
[9]Buffa G,Hua J,Shivpuri R,et al.A continuum based FEM model for friction stir welding-model development[J].Materials Science and Engineering,2006,419(1-2):389-396.
[10]严铿,曹亮,陈华斌.搅拌头倾角对FSW成形和接头力学性能的影响[J].焊接学报,2005,26(12):35-38.Yan Keng,Cao Liang,Chen Huabin.Effect of tool tilt angle on formation and mechanical property of FSW[J].Transactions of the China Welding Institution,2005,26(12):35-38.
[11]Jain R,Pal S K,Singh S B.A study on the variation of forces and temperature in a friction stir welding process:a finite element approach[J].Journal of Manufacturing Process,2016,23:278-286.
[12]Khandkar M Z H,Khan J A,Reynolds A P.Prediction of temperature distribution and thermal history during friction stir welding:input torque based model[J].Science and Technology of Welding and Joining,2003,8(3):165-174.
[13]Tello K E,Gerlich A P,Mendez P F.Constants for hot deformation constitutive models for recent experimental data[J].Science and Technology of Welding and Joining,2010,15(3):260-266.
[14]Sellars C M,Tegart W J.On the mechanism of hot deformation[J].Acta Metallurgica et Materialia,1966,14(9):1136-1139.
[15]Frigaard O,Grong O,Midling O T.A process model for friction stir welding of age hardening aluminum alloys[J].Metallurgical and Materials Transactions A,2001,32(5):1189-1200.
[16]王细波.铝合金搅拌摩擦焊完全热-力耦合模拟及流动行为研究[D].北京:清华大学,2010.
[17]Zhu Y C,Chen G Q,Qing Y S.Simulation of material plastic flow driven by non-uniform friction force during friction stir welding and related defect prediction[J].Material and Design,2016,108:400-410.