Digital twin modeling method for temperature field of friction stir welding
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摘要: 作为制造技术数字化与智能化的关键技术，数字孪生技术的发展对现有建模方法提出了新的要求. 其中，信息与物理的实时融合是数字孪生建模方法中的关键. 以搅拌摩擦焊(FSW)为例，建立了一种可在“移动热源法”数值模拟中实时融入实测温度数据的迭代式信息-物理融合算法，并论证了基于此对焊接温度场进行实时复刻的可行性. 算例试算表明，此迭代式信息-物理融合算法具有较高的可靠性，基于迭代式信息-物理融合算法的计算得到的温度相对实测温度的平均误差在5 ℃以内. 此外，采用时间步长1.5 s或2.0 s时，计算所消耗的时间将少于焊接的物理过程时间. 这使得“移动热源法”数值模拟与FSW物理过程能够以秒级的时间精度进行同步. 因此，将传感器数据实时融入与物理过程同步的数值模拟模型，是实现焊接过程数字孪生的一种可行方法.Abstract: As the key technology of digitalization and intelligentization of manufacturing, the development of digital twins (DT) technology has put forward new requirements for new simulation methods. Real-time cyber-physics fusion is a key aspect of digital twins. Taking friction stir welding (FSW) as example, a novel iterative cyber-physical fusion algorithm to realize the real-time calculation of the 3D temperature field is established. The viability of real-time simulation of 3D temperature field in FSW is demonstrated. The result shows that the proposed algorithm has high reliability, and the average error of the temperature calculated based on the proposed algorithm relative to the measured temperature in experiment is within 5 ℃. It is interesting to mention that, if a time step of 1.5 s or 2.0 s is utilized, the calculation time will be shorter than the physical process of welding. This enables numerical simulation and FSW physical processes to be synchronized with a second-level temporal precision. It is proved that integrating real-time sensor data into numerical simulation model synchronizing with physical process can be a practical method of realizing digital twin modeling of welding process.
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Keywords:
- friction stir welding /
- digital twin /
- welding process /
- temperature field /
- numerical simulation
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图 1 FSW过程数字孪生模型流程示意图
Figure 1. Flow chart of digital twin of 3D temperature field of FSW
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图 2 试验与模拟模型示意图
Figure 2. Illustrations for FSW experiment and model of simulation. (a) illustration for FSW experiment; (b) illustration for geometric model of simulation
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图 4 迭代式信息-物理融合算法流程图
Figure 4. Flow chart of the iterative cyber-physics fusion algorithm
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图 5 FSW过程的温度与总热输入情况(时间步长1.5 s)
Figure 5. Temperature and total heat input during FSW process (time step = 1.5 s)
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图 6 计算得到的焊接过程温度变化
Figure 6. Predicted temperature evolution during FSW process. (a) temperature field at 60 s; (b) temperature field at 120 s; (c) temperature field at 180 s; (d) temperature field at 240 s; (e) temperature field at 300 s; (f) temperature field at 360 s
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图 8 不同时间步长下计算得到的总热输入
Figure 8. Calculated total heat input by using different time step
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图 9 时间步长对计算的影响
Figure 9. Influence of time step on calculation. (a) temperature error between simulation and experiment; (b) average total heat input during steady welding phase
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图 10 时间步长对计算耗时的影响
Figure 10. Influence of time step on calculation time cost. (a) time cost of the whole welding process; (b) time cost of single time step
表 1 测温点的位置坐标
Table 1 Coordinate of probe locations
测温点编号 x/mm y/mm z/mm 1 −12.5 3.0 0.0 2 −2.5 4.0 0.0 3 7.5 6.0 0.0 4 17.5 7.5 0.0 
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