Thermal-solid coupling numerical simulation of laser transmission welding polycarbonate based on aluminum film intermediate layer
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摘要: 以聚碳酸酯为研究对象，使用铝膜作为中间传导层，选用高斯面热源模型，建立了金属薄膜热应力理论模型和有限元模型，应用COMSOL软件对含有铝膜中间层的聚碳酸酯激光透射焊接过程进行数值模拟. 首先分析焊接过程中焊缝不同位置处的形变和不同方向的体应变张量. 然后根据模拟出的等效应力云图和主应力云图，分析焊接过程中的应力大小及分布. 结果表明，离激光中心越近，体应变张量越大，形变越大；铝膜与聚碳酸酯间隙交界处等效应力最大，并且中心点应力随时间先增大后减小，最后趋于稳定. 运用拉伸机进行拉伸试验，将试验结果与模拟结果进行对比，发现铝膜与聚碳酸酯间隙交界处产生脆性断裂，断裂处与应力集中处相同，结果表明两者之间有良好的一致性.Abstract: This article takes polycarbonate as the research object, aluminum film is used as the intermediate conductive layer, Gaussian surface heat source model is selected, and the metal film thermal stress theoretical model and finite element model are established. The COMSOL software is used to analyze the polycarbonate laser containing the aluminum film intermediate layer. The transmission welding process is numerically simulated. First, the deformation at different positions and the volume strain tensor in different directions are analyzed. Then, according to the simulated equivalent stress cloud diagram and principal stress cloud diagram, the magnitude and distribution of stress in the welding process are analyzed. The results show that the closer to the laser center, the greater the volume strain tensor and the greater the deformation; the equivalent stress at the junction of the aluminum film and the polycarbonate gap is the largest, and the stress at the center point first increases and then decreases with time, and finally tends to stable. The tensile test was carried out with a tensile machine, and the experimental results were compared with the simulation results. It was found that brittle fracture occurred at the junction of the aluminum film and the polycarbonate gap, and the fracture was the same as the stress concentration. The results showed that there is good consistence between them.
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图 1 薄膜热应力分析
Figure 1. Thermal stress analysis of thin films. (a) unstressed; (b) bear bending moment
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图 2 体应变张量以及形变
Figure 2. Body strain tensor and deformation. (a) body strain tensor; (b) deformation
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图 5 范式等效应力图
Figure 5. Paradigm equivalent stress map. (a) equivalent stress contour; (b) principal stress diagram
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图 7 中心点等效应力随时间变化规律
Figure 7. Variation of the equivalent stress at the center point with time
表 1 单因素试验工艺参数
Table 1 Process parameters of single factor experiment
序号 激光功率P/W 焊接速度v/(mm·s−1) 吸光剂宽度W/mm 1 20 1 0.5 2 25 3 0.75 3 30 5 1 4 35 7 2 5 40 9 3 6 45 10 4 7 50 15 5 8 55 20 6 9 60 25 7 
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表 2 聚碳酸酯热物理性能参数
Table 2 Thermophysical properties of polycarbonate
玻璃转化温度Tb/℃ 热分解温度Tr/℃ 热变形温度Ts/℃ 145～150 340 132
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