Numerical simulation of residual stress in complex aluminum alloy welded structure
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摘要: 以SYSWELD有限元软件为平台，开发了基于瞬间热源的高效计算方法来模拟复杂铝合金结构的焊接残余应力. 首先以6061铝合金平板堆焊接头为研究对象，分别采用移动热源和瞬间热源计算接头的焊接残余应力，对比两者的计算结果验证瞬间热源法的有效性. 随后，将所开发的高效计算方法用于模拟6系铝合金复杂结构的焊接瞬态应力和残余应力，并将计算结果用于分析实际产品制造中开裂问题的原因，并提出了两种减缓和防止铝合金结构开裂的方案，即减小焊接热输入和增大开裂位置型材的板厚. 结果表明，铝合金结构在焊接生产制造过程中发生开裂是由该位置产生了高瞬态拉伸应力所致. 降低关键焊缝焊接热输入和增加型材板厚，均对结构开裂位置的瞬态焊接应力有一定程度的改善，且增加型材厚度的改善效果更好.Abstract: Based on SYSWELD finite element software, an efficient calculation method based on instantaneous heat source was developed to simulate the welding residual stress of complex aluminum alloy structures. Firstly, the moving heat source and instantaneous heat source were respectively used to simulate the residual stress of 6061 aluminum alloy plate surfacing welding joint and compared the results, which verified the effectiveness of the newly developed method. Subsequently, the developed efficient calculation method was used to simulate the welding transient stress and welding residual stress of 6 000 series aluminum alloy complex structure so as to analyze the causes of cracks generated in actual product manufacturing. The result shows that the high transient tensile stress is generated at this position during the welding process lead to cracking of the aluminum structure. The simulation result indicates that both solutions can improve the welding transient stress and residual stress to a certain extent, and increasing the thickness of the profile shows better improvement effect.
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图 2 6061铝合金材料参数
Figure 2. Material properties parameters of 6061 aluminum alloy. (a) thermal physical properties parameters; (b) mechanical properties parameters
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图 3 中央截面温度分布
Figure 3. Temperature distribution of cross section. (a) moving heat source; (b) instantaneous heat source
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图 4 接头表面残余应力分布
Figure 4. Residual stress distribution of joint surface. (a) longitudinal residual stress by moving heat source; (b) longitudinal residual stress by instantaneous heat source; (c) transverse residual stress by moving heat source；(d) transverse residual stress by instantaneous heat source
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图 5 截面残余应力分布
Figure 5. Residual stress distribution of cross section. (a) longitudinal residual stress by moving heat source; (b) longitudinal residual stress by instantaneous heat source; (c) transverse residual stress by moving heat source；(d) transverse residual stress by instantaneous heat source
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图 6 复杂铝合金焊接结构有限元网格模型
Figure 6. Finite element mesh model of aluminum alloy welding structure. (a) 3D element model; (b) key position
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图 10 焊缝18完成时刻关键位置y向残余应力及裂纹示意图
Figure 10. Diagram of y-direction residual stress and crack of key position after welding weld 18. (a) residual stress distribution; (b) residual stress of key position; (c) actual crack diagram
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图 11 关键位置温度及残余应力演变
Figure 11. Evolution of temperature and residual stress in key position
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