CN104573392A - Spot-weld fatigue life predicting method - Google Patents

Spot-weld fatigue life predicting method Download PDF

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CN104573392A
CN104573392A CN201510040612.8A CN201510040612A CN104573392A CN 104573392 A CN104573392 A CN 104573392A CN 201510040612 A CN201510040612 A CN 201510040612A CN 104573392 A CN104573392 A CN 104573392A
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stress
intensity factor
spot
weld
solder joint
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CN104573392B (en
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宋凯
钱涛
李光耀
成艾国
姚威
韩越
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Hunan University
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Abstract

The invention relates to a spot-weld fatigue life predicting method. The spot-weld fatigue life predicting method includes steps of 1, modeling a full vehicle and establishing a modularized spot-weld finite element model; 2, deducing spot-weld fatigue life evaluation parameter, mean stress strength factor; 3, subjecting spot-welded joints of different materials to systematic fatigue test, and subjecting the mean stress strength factor and fatigue test data of the spot-welded joints of different materials to regression analysis to obtain a curve of the spot-welded joints of different materials. The spot-weld fatigue life predicting method adopts the modularized spot-weld model to predict the spot-weld fatigue life, in actual application, only nodes of a border unit of the modularized spot-weld model are superposed with nodes of a welding structure unit, and spot-weld modeling efficiency in the full-vehicle modeling is improved.

Description

A kind of welding spot fatigue Forecasting Methodology
Invention field
The present invention relates to a kind of solder joint fatigue failure prediction, particularly relate to a kind of welding spot fatigue Forecasting Methodology.
Background technology
Resistance spot welding is welding technology traditional in automobile assembling, and the jointing form in automobile between most of parts requires to design according to resistance spot welding, and resistance spot welding is highly suitable for the overlap joint of this thin-slab construction of vehicle body.The fatigue problem of vehicle structure of about 50% is relevant with solder joint according to statistics, and the vehicle body fatigue problem of about 80% is relevant with solder joint, therefore can say that the fatigue strength of solder joint determines the permanance of automobile component.Therefore, in the means of the early stage utilization computer-aided analysis of design, carry out fatigue life prediction to vehicle body solder joint, for effectively reducing production cost, shorten the Automobile Design construction cycle, the quality improving product has important realistic meaning.
At present, welding spot fatigue prediction mainly contains two kinds of methods: a kind of is LBF method based on power, the method adopts beam element simulation nugget, by acting on the force and moment on nugget beam element, calculate that the structural stress on welded blank evaluates welding spot fatigue according to certain mathematical formulae, can not transmit the torsional moment on shell unit due to beam element, and the calculating of structural stress adopts more empirical parameter, therefore precision of prediction is lower; Another kind is the LMS Forecasting Methodology based on stress, the method adopts the solder joint model become more meticulous very much, directly predict welding spot fatigue by the local stress of FEM (finite element) calculation welded blank, there is certain precision of prediction, but be applied to car load solder joint fatigue prediction in, then modeling and counting yield on the low side.
Summary of the invention
The object of the invention is to solve that precision of prediction existing for existing solder joint fatigue Forecasting Methodology is on the low side, modeling and the problem such as counting yield is on the low side.
Technical scheme of the present invention there is provided a kind of welding spot fatigue Forecasting Methodology, it is characterized in that:
Step 1, Full Vehicle Modelling, set up modularization solder joint finite element model;
Step 2, derivation welding spot fatigue evaluation parameter: mean stress intensity factor
Step 3, the tack-weld of different materials is carried out to the torture test of system, will carry out regretional analysis with the fatigue data of the tack-weld of different materials, obtain different materials tack-weld curve.
Further, in step 2, mean stress intensity factor derivation is as follows:
(1) the node force and moment of each node around solder joint nugget in whole vehicle model can be obtained under different working condition by cae analysis, and is converted into the nodal force F under each node local coordinate system by coordinate transform x, F y, F zwith node moment M x, M y, M z;
(2) by nodal force F x, F y, F zbe converted to linear force f x, f y, f z, node moment M x, M y, M zbe converted to linear moment m x, m y, m z;
(3) respective nodes place structural stress σ is calculated m, σ b, wherein, by the linear force and moment of node each around solder joint, obtain the structural stress at respective nodes place by formula (2):
σ m＝f y/t
σ b＝6m x/t 2(2)
In formula, σ mfor the membrane stress of Nodes each around solder joint, σ bfor the bending stress of Nodes each around solder joint, f y, m xbe respectively the linear force and moment on y, x direction under local coordinate system, t is the thickness of welding motherboard;
(4) Nodes structural stress is carried out to the correction of Crack Extension angle α, wherein, the structural stress through solder joint actual crack expanded-angle α revises:
σ mxz＝(f ysinα-f zcosα)sinα/t
In formula, σ mxzfor the membrane stress revised through α, σ bxzfor the bending stress revised through α, t is welding motherboard thickness, and α is actual crackpropagation angle, f y, f z, m xbe respectively the linear force and moment on y, z, x direction under local coordinate system;
(5) to the stress intensity factor Δ K of membrane stress m, bending stress stress intensity factor Δ K b, total stress intensity factor Δ K calculates, wherein total stress intensity factor:
ΔK = Δ K m + Δ K b = πa [ σ mxz f m ( a t r ) + σ bxz f b ( a t r ) ] - - - ( 4 )
In formula: Δ K mfor the stress intensity factor of corresponding membrane stress, Δ K bfor the stress intensity factor of corresponding bending stress, Δ K is total stress intensity factor, for the Geometric corrections coefficient of the corresponding membrane stress of stress intensity factor, for the Geometric corrections coefficient of the corresponding bending stress of stress intensity factor;
(6) to mean stress intensity factor calculate, get the mean stress intensity factor of crackle on thickness of slab direction in expansion process evaluation parameter as welding spot fatigue:
ΔK ‾ = ∫ a t = 0 a t = 1 ΔKd a t = ∫ a t = 0 a t = 1 πa [ σ mxz f m ( a t ) + σ bxz f b ( a t ) ] d a t - - - ( 7 )
Calculate:
Further, the nugget of solder joint uses two layer entities unit simulation, and every layer is made up of four solid elements, and form an equilateral octagon, diameter gets the actual diameter of nugget, and the supposition of nugget material is consistent with mother metal
Beneficial effect of the present invention:
(1), the present invention adopts a kind of modularization solder joint model to predict welding spot fatigue, only the node of modular solder joint model boundary unit need be overlapped with welded structure cell node in a particular application, improve the efficiency of solder joint modeling in Full Vehicle Modelling.
(2) this model carries out solder joint fatigue simulation analysis and mainly contains two advantages: one is use multiple body unit simulation nugget, and has distinguished separately nugget, heat-affected zone and mother metal district, more meets the physical geometric of solder joint reality; Two is that the structural stress result of gained is by the impact not by sizing grid owing to adopting modularization model to be fixed by solder joint size of mesh opening.
(3) in the welding spot fatigue prediction of reality, the node force and moment of each node around nugget is first obtained by finite element analysis, the corresponding structural stress of each node is obtained by nodal force and Calculating Torque during Rotary according to acting principle, and according to crackle on thickness of slab direction true extension angle it is revised, structural stress thus through revising can calculate the stress intensity factor at respective nodes place, and then obtains one at the evaluation parameter of the mean stress intensity factor of solder joint crackle on its actual extensions path as welding spot fatigue.
(4) owing to adopting mean stress intensity factor as the evaluation parameter of welding spot fatigue, only need calculate node force and moment around solder joint as input, and welding spot fatigue considers the impact of crackle true extension angle in calculating, therefore counting yield and precision of prediction are relatively high.
Accompanying drawing explanation
Fig. 1 is the process flow diagram of a kind of welding spot fatigue Forecasting Methodology of the present invention;
Fig. 2 is solder joint modular finite meta-model unit of the present invention;
Fig. 3 is node whole and part coordinate system of the present invention;
Fig. 4 is typical spot welding lap joint fatigue failure mode schematic diagram;
Fig. 5 is the constituent schematic diagram of welding sheet metal structural stress;
Fig. 6 is torture test tack-weld specimen size schematic diagram;
Fig. 7 is the load amplitude-fatigue lifetime double-log distribution schematic diagram of torture test gained sample;
Fig. 8 is the tack-weld modular finite meta-model schematic diagram set up according to torture test tack-weld size;
Fig. 9 is the double-log distribution schematic diagram of mean stress intensity factor-fatigue lifetime.
Embodiment
Below with reference to accompanying drawing 1-9, technical scheme of the present invention is described in detail
The invention provides a kind of welding spot fatigue Forecasting Methodology, comprise the following steps:
Step 1, Full Vehicle Modelling, set up modularization solder joint finite element model
In Full Vehicle Modelling, the modularization solder joint finite element model set up as shown in Figure 2, the nugget of solder joint uses two layer entities unit simulation, in order to solve the problem that solder joint finite element model mates with structured grid, every layer is made up of four solid elements, form an equilateral octagon, diameter gets the actual diameter of nugget, and the supposition of nugget material is consistent with mother metal.Then, the basic grid size of 10 × 10mm is progressively transitioned into by three circle shell units.
One deck shell grid is covered in nugget district upper and lower surface, for solving the problem that shell grid mates with entity grid node degree of freedom, to weld circumnuclear first lap mesh definition is solder joint heat-affected zone, get 2mm along the width on spot size direction, solder joint heat-affected zone material thickness, type are consistent with welding base metal.Two remaining hoop net lattice are solder joint mother metal district, and its outermost border is made up of two element sides, thus can complete excessive to basic grid size of solder joint size of mesh opening.
After establishing whole vehicle model, just can carry out to it node force and moment that finite element analysis obtains each node around different operating mode under body solder joint nugget, then convert node force and moment to mean stress intensity factor by Theory of Fracture Mechanics then should can be used as the evaluation parameter of welding spot fatigue, by the mean stress intensity factor of Nodes each around solder joint with the tack-weld of its respective material curvilinear correlation joins, and just can obtain N fatigue lifetime of corresponding solder joint.Below by butt welding point Fatigue Life Assessment parameter derivation and the tack-weld of different materials the acquisition of curve describes in detail.
Step 2, derivation welding spot fatigue evaluation parameter: mean stress intensity factor
After adopting above-mentioned modularization modeling method to set up car load and solder joint finite element model, need the evaluation parameter deriving welding spot fatigue, concrete derivation is as follows:
(1) the node force and moment of each node around solder joint nugget in whole vehicle model can be obtained under different working condition by cae analysis, and is converted into the nodal force F under each node local coordinate system by coordinate transform x, F y, F zwith node moment M x, M y, M z.Converted coordinate is shown in Fig. 3, and wherein (x ', y ', z ') be global coordinate system, the local coordinate system that (x, y, z) is certain node.
(2) by nodal force F x, F y, F zbe converted to linear force f x, f y, f z, node moment M x, M y, M zbe converted to linear moment m x, m y, m z
According to acting principle through type (1) by nodal force F x, F y, F zchange into the corresponding linear force f of each node x, f y, f z, following formula be namely by node x each around nugget to nodal force F x1, F x2, F x3f x (n-1)calculate obtain each node x to linear force f x1, f x2, f x3f x (n-1)matrix Formula:
F x 1 F x 2 F x 3 . . . . . . F x ( n - 1 ) = 1 1 + 1 n - 1 3 1 1 6 0 0 . . . 1 n - 1 6 1 1 6 1 1 + 1 2 3 1 2 6 0 . . . . . . 0 1 2 6 1 2 + 1 3 3 1 3 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 n - 1 6 0 0 0 1 n - 2 6 1 n - 2 + 1 n - 1 3 × f x 1 f x 2 f x 3 . . . . . . f x ( n - 1 ) - - - ( 1 )
In formula: as shown in Figure 3,1,2,3 ... n-1 is the numbering of each node around nugget, and have eight nodes due to around the solder joint model nugget that adopts herein, so n gets 9, again because nugget is ring-type, node 1 overlaps with n, so nodal force only need get n-1; F x1, F x2, F x3f x (n-1)for each node x to nodal force; f x1, f x2, f x3f x (n-1)for each node x to linear force; l 1, l 2, l 3l n-1for nodal pitch each around nugget; Similar with it, around solder joint each node y to z to linear force also can by y to z to nodal force obtained by identical Matrix Formula, only need change the subscript x in formula into y, z.
Same, node linear moment m x, m y, m zalso can by node moment M x, M y, M zobtained by identical transition matrix, only need change the F in Matrix Formula into M, f changes m into.
(3) respective nodes place structural stress σ is calculated m, σ b
By the linear force and moment of node each around solder joint, the structural stress at respective nodes place can be obtained by formula (2):
σ m＝f y/t
σ b＝6m x/t 2(2)
In formula, σ mfor the membrane stress of Nodes each around solder joint, σ bfor the bending stress of Nodes each around solder joint, f y, m xbe respectively the linear force and moment on y, x direction under local coordinate system, t is the thickness of welding motherboard.
(4) Nodes structural stress is carried out to the correction of Crack Extension angle α
Fatigue failure due to solder joint is that the Crack Extension owing to running through thickness of slab causes, but crackle is not be parallel to thickness of slab direction completely in the expansion in thickness of slab direction, but α at angle, the size of angle [alpha] and the relating to parameters such as material, thickness of slab of solder joint joint, Figure 4 shows that the typical fatigue failure mode of overlapped points soldered joint.The structural stress revised through solder joint actual crack expanded-angle α then can be obtained by formula (3):
σ mxz＝(f ysinα-f zcosα)sinα/t
Figure 5 shows that the constituent of welding sheet metal structural stress, wherein σ mxzfor the membrane stress revised through α, σ bxzfor the bending stress revised through α, t is welding motherboard thickness, and α is actual crackpropagation angle, f y, f z, m xbe respectively the linear force and moment on y, z, x direction under local coordinate system.
(5) to the stress intensity factor Δ K of membrane stress m, bending stress stress intensity factor Δ K b, total stress intensity factor Δ K calculates
Total stress intensity factor can be obtained by formula (4):
ΔK = Δ K m + Δ K b = πa [ σ mxz f m ( a t r ) + σ bxz f b ( a t r ) ] - - - ( 4 )
Wherein Δ K mfor the stress intensity factor of corresponding membrane stress, Δ K bfor the stress intensity factor of corresponding bending stress, Δ K is total stress intensity factor, for the Geometric corrections coefficient of the corresponding membrane stress of stress intensity factor, for the Geometric corrections coefficient of the corresponding bending stress of stress intensity factor, expression formula is as follows:
f m ( a t r ) = [ 1.1214 - 1.6349 ( a t r ) + 7.3168 ( a t r ) 2 - 18.7746 ( a t r ) 3 + 31.8028 ( a t r ) 4 - 33.2295 ( a t r ) 5 + 19.1286 ( a t r ) 6 - 4.609 ( a t r ) 7 ] / ( 1 - a t r ) 3 / 1 - - - ( 5 )
f b ( a t r ) = [ Σ n = 0 12 C n ( a t r ) n ] / ( 1 - a t r ) 3 / 2 - - - ( 6 )
In formula, C 0=1.12152, C 1=-3.04057, C 2=10.49184, C 3=-36.6678, C 4=110.099, C 5=-255.68184, C 6=421.97167, C 7=-440.50866, C 8=199.37326, C 9=123.93056, C 10=-237.97164, C 11=136.17068, C 12=-28.91005; A is the crack length existed in certain moment, t rfor fatigue break critical crack length, t r=t/sin α.
(6) to mean stress intensity factor calculate
Because the crack propagation life of tack-weld on thickness of slab direction accounts for more than 80% of its whole fatigue lifetime, therefore we can reasonably suppose fatigue break critical crack length t r≈ t, and fatigue crack from a=0 until rupture when expanding to a=t, then the mean stress intensity factor of desirable crackle on thickness of slab direction in expansion process evaluation parameter as welding spot fatigue:
ΔK ‾ = ∫ a t = 0 a t = 1 ΔKd a t = ∫ a t = 0 a t = 1 πa [ σ mxz f m ( a t ) + σ bxz f b ( a t ) ] d a t - - - ( 7 )
Calculate:
In above-mentioned computing formula, the physical quantity that identical letter representation is identical, the therefore implication of repeated description corresponding letters in no longer each formula.
Step 3, the tack-weld of different materials is carried out to the torture test of system, will carry out regretional analysis with the fatigue data of the tack-weld of different materials, obtain different materials tack-weld curve.
The tack-weld of different materials is carried out to the torture test of system, will carry out regretional analysis with the fatigue data of the tack-weld of different materials, can obtain corresponding to different materials tack-weld curve.With the S-N class of a curve in traditional analysis of fatigue seemingly, in real vehicle analysis of fatigue available these the fatigue lifetime of curve butt welding point carries out finite element simulation prediction, is namely obtained the mean stress intensity factor of the different solder joint of vehicle body by finite element analysis computation again by corresponding curve obtains corresponding fatigue lifetime.
To one be provided to adopt context of methods to obtain DP600GI material point soldered joint below the method example of curve:
First the shear fatigue test of design point soldered joint is wanted.Choose a kind of high-strength steel material DP600GI as subjects, the thickness of slab of spot-welding sample is made 0.8mm, 1.0mm, 1.5mm and 1.8mm tetra-kinds, in order to ensure the consistance of the tack-weld obtained, the physical dimension of all samples is all consistent (see Fig. 6), welding steel is all the combination of thickness of the same race, and Spot size is unified is 7.0mm.
Because vehicle body solder joint mainly bears shear-type load, the shear fatigue life-span of each solder joint exemplar is only paid close attention in test, the spot welding exemplar of HSLA340GI 4 kinds of thickness of slab combinations is carried out shear fatigue experiment on electo hydraulic servocontrolled fatigue testing machine, in process of the test, loaded load is 0.1 than R, and loading frequency is 10Hz.The fatigue data of torture test gained can represent (see Fig. 7) with the double-log distribution plan of load amplitude-fatigue lifetime.
Next the Fatigue Life Assessment parameter of the tack-weld being obtained different-thickness by finite element analysis is needed first modularization tack-weld finite element model (see Fig. 8) is set up according to the exemplar size of torture test, for keeping the consistance with torture test condition, Spot size gets 7.0mm, sample one end retrains whole six-freedom degree, other end imposed load, the constraint of load stress point is except whole degree of freedom of loading direction.Material properties is linear elasticity, and elastic modulus is 210GPa, and Poisson ratio is 0.3, and density is 7.85 × 10 3kg/m 3.
Finite element analysis is carried out to the model built up and adopts derivation method herein to calculate the mean stress intensity factor of different-thickness tack-weld and carrying out double-log regretional analysis with data fatigue lifetime of solder joint, analysis result is shown in Fig. 9.Upper as can be seen from figure, some fatigue lifetime of the solder joint exemplar of all different-thickness is distributed near fitting a straight line all closely, and the degree of correlation of fitting a straight line reaches R 2=-0.95, therefore we can obtain a master curve is as follows:
ΔK ‾ = 87799 N - 0.2201 - - - ( 9 )
Then namely this curve is DP600GI tack-weld curve, other materials tack-weld curve can also adopt same method to be obtained by torture test.
Although disclose in detail the present invention with reference to accompanying drawing, it should be understood that these descriptions are only exemplary, be not used for limiting application of the present invention.Protection scope of the present invention by appended claims, and can be included in when not departing from scope and spirit for inventing various modification, remodeling and the equivalents done.

Claims (3)

1. a welding spot fatigue Forecasting Methodology, is characterized in that:
Step 1, Full Vehicle Modelling, set up modularization solder joint finite element model;
Step 2, derivation welding spot fatigue evaluation parameter: mean stress intensity factor
Step 3, the tack-weld of different materials is carried out to the torture test of system, will carry out regretional analysis with the fatigue data of the tack-weld of different materials, obtain different materials tack-weld curve.
2. welding spot fatigue Forecasting Methodology according to claim 1, is characterized in that: in step 2, mean stress intensity factor derivation is as follows:
(1) the node force and moment of each node around solder joint nugget in whole vehicle model can be obtained under different working condition by cae analysis, and is converted into the nodal force F under each node local coordinate system by coordinate transform x, F y, F zwith node moment M x, M y, M z;
(2) by nodal force F x, F y, F zbe converted to linear force f x, f y, f z, node moment M x, M y, M zbe converted to linear moment m x, m y, m z;
(3) respective nodes place structural stress σ is calculated m, σ b, wherein, by the linear force and moment of node each around solder joint, obtain the structural stress at respective nodes place by formula (2):
σ m＝f y/t
σ b＝6m x/t 2(2)
In formula, σ mfor the membrane stress of Nodes each around solder joint, σ bfor the bending stress of Nodes each around solder joint, f y, m xbe respectively the linear force and moment on y, x direction under local coordinate system, t is the thickness of welding motherboard;
(4) Nodes structural stress is carried out to the correction of Crack Extension angle α, wherein, the structural stress through solder joint actual crack expanded-angle α revises:
σ mxz＝(f ysinα-f zcosα)sinα/t
In formula, σ mxzfor the membrane stress revised through α, σ bxzfor the bending stress revised through α, t is welding motherboard thickness, and α is actual crackpropagation angle, f y, f z, m xbe respectively the linear force and moment on y, z, x direction under local coordinate system;
(5) to the stress intensity factor Δ K of membrane stress m, bending stress stress intensity factor Δ K b, total stress intensity factor Δ K calculates, wherein total stress intensity factor:
In formula: Δ K mfor the stress intensity factor of corresponding membrane stress, Δ K bfor the stress intensity factor of corresponding bending stress, Δ K is total stress intensity factor, for the Geometric corrections coefficient of the corresponding membrane stress of stress intensity factor, for the Geometric corrections coefficient of the corresponding bending stress of stress intensity factor;
(6) to mean stress intensity factor calculate, get the mean stress intensity factor of crackle on thickness of slab direction in expansion process evaluation parameter as welding spot fatigue:
Calculate:
3. welding spot fatigue Forecasting Methodology according to claim 1, it is characterized in that: the nugget of solder joint uses two layer entities unit simulation, and every layer is made up of four solid elements, forms an equilateral octagon, diameter gets the actual diameter of nugget, and the supposition of nugget material is consistent with mother metal.
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