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基于解析热源与ALE法模拟比较的搅拌摩擦焊固相温度调节机制分析

Analysis of solid-phase temperature regulation mechanism of friction stir welding by simulation comparison between analytical heat source and ALE methods

  • 摘要: 针对搅拌摩擦焊独立于工艺条件而维持固相温度区间的固有属性,分别采用解析热源模型和机械热力耦合模型不同生热方式模拟搅拌头−铝焊件界面摩擦产热过程,以剖析焊接热物理量及工艺参数对热循环曲线的影响,旨在揭示摩擦焊行为内蕴的固相温度调节机制. 为此,根据点焊过程等效热载荷建立高斯面−双椭球体复合移动热源、任意的拉格朗日−欧拉自适应网格(arbitrary lagrange euler,ALE)仿真模型,结合焊装热边界条件进行瞬态温度场仿真,并利用热电偶多点实测的温度分布验证场预测的有效性. 结果表明,ALE法比解析法的数值模拟精度提高6.3%;主轴转速、轴肩尺寸的参数极限变化所引起的中心峰值温度波动范围为477 ~ 589 ℃,且峰前温升速率不断递减. 主要归因于与温度变化高度负相关的合金流变屈服应力,高温软化行为促使材料抗变形能力和界面摩擦系数减小,从而通过负反馈调节作用限制产热率递升.

     

    Abstract: In view of the inherent property of friction stir welding, which maintains the solid phase temperature range independently of the process conditions, an analytical heat source model and mechanical thermal coupling model were used to simulate the interface friction heat generation process between the stirring head and aluminum welds, respectively. It aims to analyze the influence of welding thermal physical quantities and process parameters on the thermal cycle curve and reveal the solid phase temperature regulation mechanism inherent in friction stir welding behavior. Therefore, the simulation model of a Gaussian surface and double ellipsoid complex moving heat source and an arbitrary Lagrange-Eulerian (ALE) adaptive mesh was established according to the equivalent thermal load of the spot welding process. The transient temperature field was simulated according to the welding thermal boundary conditions, and the temperature distribution measured at multiple points using thermocouples was utilized to verify the validity of the field prediction. The results show that the numerical simulation accuracy of the ALE method is 6.3% higher than that of the analytical method. The central peak temperature fluctuates from 477 ℃ to 589 ℃ due to the parameter limit changes of the spindle speed and shoulder size, and the pre-peak temperature rise rate decreases continuously. This is mainly due to the rheological yield stress of the alloy, which is highly negatively related to the temperature change. The softening behavior at high temperature reduces the deformation resistance and interfacial friction coefficient of the material, thus limiting the heat production rate to rise through negative feedback regulation.

     

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