Numerical analysis of transient process in laser keyholing spot welding
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摘要: 考虑工件表面等离子体作用，建立了小孔和熔池传热与传质耦合的穿孔点焊数值分析模型. 采用随小孔形状变化的自适应热源模型，热源形态依小孔形状变化而实时改变. 模型考虑了蒸发现象所引起的质量转换和能量损失，利用焓–孔介质法处理焊接过程动量损耗. 主要考虑液态金属蒸发所带来的反冲压力、表面张力和液体静压力并通过流体体积方程计算小孔壁面. 结果表明，小孔形成直至穿孔过程都可能产生向上和向下的飞溅、焊瘤和余高. 激光的瑞利散射、工件表面等离子体的热效应，激光束反射和等离子体膨胀作用，使得工件上/下的焊缝宽度比中间略大. 模拟计算值与试验结果比较，二者在形状和尺寸基本吻合.Abstract: Considering plasma effect on the surface of the workpiece, a numerical simulation model of keyhole and weld pool coupled with heat and mass transfer was established. The adaptive heat source model was used with the change of shape of keyhole in real time. Mass transfering and energy lossing caused by evaporation was considered in the model, and the momentum sinking due to solidification was dealt with enthalpy-porosity technique. The keyhole wall was calculated by fluid volume equation, mainly considering recoil pressure induced by the metal evaporation, surface tension and hydrostatic pressure. The results demonstrated that, spatters are shaped such as weld flash and reinforcement after keyhole formation and perforation. The upper and lower welding width is slightly larger than the middle induced by raleigh scattering of laser, reflection and expansion of plasma. The calculated values were basically consistent with the experimental results in shape and size of the weld.
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Keywords:
- spot welding /
- deep penetration welding /
- transient process /
- raleigh scattering /
- keyhole
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