CN105005650A - Quantitative evaluation method for aluminum profile extrusion welding quality - Google Patents
Quantitative evaluation method for aluminum profile extrusion welding quality Download PDFInfo
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Abstract
The invention discloses a quantitative evaluation method for aluminum profile extrusion welding quality. The method comprises the following steps of: performing mesh division and extrusion parameter setting on an established three-dimensional extrusion model, and performing numerical simulation on an aluminum profile extrusion welding process, so as to obtain a material flowing pattern of the whole extrusion and welding process of a metal flow; extracting data information of all welding points on a welding surface, namely a pressure, stress and three-dimensional coordinates; processing extracted data information, so as to obtain discrete three-dimensional coordinate points; and fitting the obtained discrete three-dimensional coordinate points into a smooth curved surface, and obtaining a volume of a spatial body enclosed by the fitted surface and a bottom vertical projection. According to the method provided by the invention, the extrusion welding quality evaluation is expanded from a two-dimensional model to a three-dimensional model, welding quality evaluation is expanded from using data of only one welding line to using data of the whole welding surface, and a basic qualitative description is expanded to an accurate quantitative description, thereby implementing a quantitative evaluation on the extrusion welding quality of three-dimensional hollow profiles.
Description
Technical field
The invention belongs to extruded metal profile technical field, particularly a kind of quantitative evaluating method of Extrusion Process of Aluminum Alloy Profile welding quality, for the welding quality of the assessment aluminum extrusion process medium section of accurate quantitative analysis.
Background technology
Aluminium alloy extrusions, because of advantages such as its density is low, outward appearance is good, specific strength is high, good corrosion resistances, achieves application widely in fields such as track traffic, Aero-Space, automobile, boats and ships, electric power, the energy, buildings.According to statistics, within 2012, global aluminum processing material output reaches 4,800 ten thousand tons, wherein squeeze wood is more than 1,950 ten thousand tons, and aluminium section bar is constantly to maximization, the flat broadening of thin-walled and the complicated future development of section, the hollow industrial aluminum profile proportion of complicated big cross section improves [Liu Jingan day by day, the development characteristic of contemporary aluminium alloy extruded new material and market analysis. resource recovery, 2014 (03): 19-22].
The hollow aluminum section of current more than 90% adopts shunting combination extrusion technique to produce.In extrusion process, high temperature ingot casting passes through extrusion die under the promotion of pressure ram, because of the existence of mold diversion bridge, metal is divided into several strands of metal flows when mould, under high temperature and high pressure environment, due to acting by external hydrostatic pressure, metal flow is again converged again and is merged, when therefore adopting diffluence combination die extruding to produce, owing to shunting the existence of bridge in bonding container, inevitably there is seam line in aluminium shape surface, is referred to as longitudinal seam line.The forming process of seam line is the solid-state fusion process of metal material in fact, recombinate along with micromechanism, as [the Den Bakker AJ such as recovery and recrystallization and grain growth, Werkhoven RJ, Sillekens WH, Katgerman L.Towards predictive control of extrusion weld seams:an integrated approach.Key EngineeringMaterials.2010; 424:9-17].Compared with other positions of section bar, the mechanical property at longitudinal seam line place is poor, and the position that in normally whole hollow profile, intensity is minimum, section bar often first destroys herein.In addition, mold diversion hole number is more, and corresponding seam number of lines is more, and the inner potential seam defect of complicated big cross section hollow profile is more.Therefore, increasingly extensive today is applied at complicated big cross section hollow aluminum section, seam line formation mechenism and assess its welding quality exactly to the raising quality of production and particularly important [the Loukus A of productivity effect in research hollow aluminum section extruding seam process, Subhash G, Imaninejad M.Mechanical properties and microstructural characterization of extrusion weldsin AA6082-T4.Journal of Materials Science 2004; 39:6561-6569].
Produce due to reality extruding and complete seam in the bonding container of High Temperature High Pressure, material fusion process is difficult to directly be monitored by physical means, therefore seam criterion combined with numerical simulation is study at present to extrude the most frequently used method of seam, by carrying out numerical simulation to Extrusion Process of Aluminum Alloy Profile seam process, related data on the seam face of extracting, then utilizes seam criterion to calculate Weld strength.Seam criterion conventional at present mainly contains pressure versus time criterion (Q criterion) and pressure versus time-flow velocity criterion (K criterion).When the integrated value (being called Weld strength) of the pressure versus time in Q or K criterion or pressure versus time-flow rate expression reaches the material seam limit, just think that the welding quality of section bar is good.But, at present the modeling effort of extruding seam is confined to mostly to the two-dimentional extrusion process of section configuration simple symmetric form hollow profile, rarely has the welding quality evaluation study that aluminium section bar D extrusion process is carried out.In addition, at present about the quantitative examination of seam criterion, mostly also all rest on the two dimensional model of simplification, what namely calculate is the Q value or K value that on seam face, seam path is corresponding, there is not yet and utilizes all bonding point data on whole seam face to carry out quantitative examination truly to D extrusion welding quality.
Summary of the invention
The present invention is in order to solve the problem, propose a kind of quantitative evaluating method of Extrusion Process of Aluminum Alloy Profile welding quality, this method can carry out transient simulation to aluminium section bar D extrusion process, the valid data of all bonding points in the seam face of extraction, and based on extracted data, in conjunction with seam criterion, qualitative assessment is exactly carried out to D extrusion welding quality.
To achieve these goals, the present invention adopts following technical scheme:
A quantitative evaluating method for Extrusion Process of Aluminum Alloy Profile welding quality, comprises the following steps:
(1) D extrusion model is created, and model is imported in finite element software, carry out stress and strain model and squeezing parameter setting, numerical simulation is carried out to Extrusion Process of Aluminum Alloy Profile seam process, obtains metal flow and contact from being diverted to the material flowing law that the whole extruding seam process of complete seam occurs to section bar extrusion work strip the seam of beginning, seam face again;
(2) data messages such as the pressure of all bonding points on seam face, stress and three-dimensional coordinate are extracted;
(3) data message of extraction is processed, obtain discrete three dimensional space coordinate point;
(4) three dimensions discrete for gained point is fitted to a smooth surface, and obtain the space body volume that this fitting surface and plane perpendicular project coated, be the K value that seam path on seam face is corresponding.
In described step (1), specifically comprise:
(1-1) utilize UG to create D extrusion model derive stl file, stl file to be imported in Forge-3D and to carry out stress and strain model and squeezing parameter is arranged;
(1-2) friction kind, coefficient and heat transfer parameter are set according to the kind of mould and the die region of material flowing therethrough.
In described step (2), the correlation parameter being extracted all seam nodes on seam face by the aftertreatment of Forge-3D software comprises node pressure p, node stress σ, node flow velocity v and node coordinate (x, y, z).
In described step (2), the number of bonding point is determined by mesh-density, and stress and strain model is finer and closely woven, and seam nodes is more.
In described step (3), according to extracted node pressure p, node stress σ, determine that each bonding point k value is: k
ij=p
ij/ σ
ij, i.e. Z axis coordinate in space coordinates.
In described step (3), according to the actual coordinate (x, y, z) of extracted node, convert thereof into seam areal coordinate l
i, m
j, i.e. X, Y-axis coordinate in space coordinates; Three dimensional space coordinate point (the l of final acquisition series of discrete
i, m
j, k
ij).
In described step (4), first call discrete three dimensions point coordinate data, then adopt stress and strain model function to carry out grid data division to XY plane and seam face, whole XY face is divided into the identical surface elemant of size; By difference functions, interpolation is carried out to Z-direction data; With drawing function, the data fitting after interpolation is become smooth surface; Finally by summing function, space body volume corresponding for all surface elemants is added up, K value can be obtained.
Beneficial effect of the present invention is:
(1) transient simulation can be carried out to hollow profile whole extruding seam process, obtain the flowing law of each single metal stream and the data result of extrusion process in real time.
(2) K seam criterion volume-based model is proposed, and according to its physical significance using the standard of K value size as quantification welding quality.
(3) based on welding quality criterion, by two dimensional model, three-dimensional model is extended to the evaluation of extruding welding quality, namely being extended to from the data only utilized a seam line utilizes the data in whole seam face to evaluate welding quality, and be extended to accurate quantitative description by basic qualitative description, achieve the qualitative assessment to three-dimensional hollow profile extrusion welding quality.
(4) based on this inventive method, the factors such as different squeezing parameter and mould structure of can studying are to the quantitative effect of welding quality, and assess the impact of this factor on whole seam plane zones of different welding quality, the production and processing for reality provides theoretical foundation and Technical Reference.
(5) the present invention is equally applicable to the quantitative evaluation of the shape welding quality that other are processed by extruding seam.
Accompanying drawing explanation
Fig. 1 is square tube section section configuration of the present invention and dimensional drawing;
Fig. 2 is three-dimensional welding quality evaluation volume model schematic of the present invention;
Fig. 3 is three-dimensional mould geometric model of the present invention;
Fig. 4 (a) is that in transient simulation of the present invention, after blank shunting, middle part starts the seam face that arrives;
Fig. 4 (b) is that in transient simulation of the present invention, metal flow center section is merging and generating portion seam mutually;
Fig. 4 (c) is that in transient simulation of the present invention, metal flow flows to other positions of bonding container and is full of bonding container gradually under mould constraint;
Fig. 4 (d) is that in transient simulation of the present invention, extrusion profile is just extruded work strip completely and complete seam occurs;
Fig. 5 is the actual distribution figure of all seam nodes on seam face in extrusion mode of the present invention;
Fig. 6 is pressure and stress axis (k after analog result of the present invention
ijvalue) fitting surface cloud charts;
Fig. 7 is the K value under model extrusion stability stage of the present invention difference extruding step number.
Embodiment:
Below in conjunction with accompanying drawing and embodiment, the invention will be further described.
By adopting the method for a kind of qualitative assessment D extrusion seam process welding quality proposed by the invention, achieving the transient simulation to square tube extruding as shown in Figure 1, and quantitative evaluation is carried out to aluminium section bar D extrusion process welding quality.
(1) theoretical preparation
For the application of seam criterion is extended to seam face by seam line, the calculating of Weld strength must consider on seam face to welding quality contributive likely seam path, i.e. the integration of all p/ σ values in seam face.According to the mathematical description of K seam criterion integral expression, the volume that K integrated value can be coated by three dimensions as shown in Figure 2 represents.Wherein X-axis and Y-axis are respectively height l and the width m in seam face, and Z axis is the p/ σ value that in seam face, selected bonding point is corresponding, and bottom surface is projected as seam face.If obtain the space body volume that whole p/ σ curved surface and plane perpendicular project coated, just to obtain in seam face the Weld strength K value likely corresponding to seam path, also just complete the evaluation of D extrusion welding quality.This is proposed K seam criterion volume-based model.
(2) Modling model
The step of qualitative assessment D extrusion process welding quality is now set forth for the first-class wall thickness square tube section shown in Fig. 1.This extrusion profile length of side is 27mm, and wall thickness is 4mm, and fillet radius is 1mm, and round radius is 3mm, and section bar sectional area is 361.62mm
2, section bar material therefor is AA6061.
First utilize UG to create D extrusion model derive stl file, stl file to be imported in Forge-3D and to carry out stress and strain model and squeezing parameter is arranged.Arranging of portion extrusion technological parameter is as follows: blank temperature is 480 DEG C, and mold preheating temperature is 450 DEG C, and dummy block speed is 0.5mm/s, and bar diameter is 80mm, and extrusion ratio is 13.9.
When adopting Forge-3D to simulate the transient state extruding of square tube, friction factor changes to some extent according to the difference of material flowing therethrough die region.Friction and heat transfer parameter are arranged as follows: be shearing friction between blank and recipient and dies cavity, friction factor is 0.85; Blank and work strip place rub as Coulomb friction, and friction factor is 0.3.The heat transfer coefficient of blank and miscellaneous part (comprising recipient, dummy block, mould) is 3000W/ (m
2k).
(3) simulation result analysis
In realistic simulation, in order to save operation time, utilize Forge-3D to simulate 1/8th square tube transient state extruding seam processes, metal flow can be obtained from just, contact the material mobility status that this whole process of complete seam occurs to section bar extrusion work strip in seam face, as shown in Figure 4.Fig. 4 (a) represents that blank is divided into two strands of metal flows under the effect of shunting bridge after tap hole, and first middle part metal flow comes in contact at seam face place, and this represents that the material flow rates of metal flow in middle part is higher than periphery; Fig. 4 (b) represents that center section metal flow is merging and generating portion seam mutually; Fig. 4 (c) represents that metal flow closes the flowing of other positions, room at mould constraint down weld, and bonding container is full of by metal flow gradually; Fig. 4 (d) represents that extrusion profile just extrudes work strip completely, and complete seam now occurs, and extrusion reaches the extrusion stability stage.
(4) extraction of seam face data and process
For utilizing K seam criterion (formula) to obtain K value on whole seam face, i.e. the volume of Fig. 2, must obtain by the three-dimension curved surface of bonding point data institute matching.For this reason, extracted the parameter of all seam nodes on seam face by the aftertreatment of Forge-3D software: node pressure p, node stress σ, node flow velocity v, node coordinate (x, y, z) etc.Fig. 5 represents the actual distribution figure of bonding point on seam face, has marked seam face Width, seam face short transverse, the direction of extrusion and position, mould outlet place in figure.In simulation, how many nodes is determined by mesh-density: stress and strain model is finer and closely woven, and node is more, and simulation precision is higher, but required time is longer.Therefore under Computing ability and permission operation time situation, for obtaining K value more accurately, stress and strain model should be fine and closely woven as far as possible.
Based on Matlab, according to extracted node pressure p, node stress σ, determine that the k value of each bonding point is for k
ij=p
ij/ σ
ij, i.e. Z axis coordinate in space coordinates; Actual coordinate (x, y, z) according to extracting node converts seam areal coordinate l to
i, m
j, i.e. X, Y-axis coordinate in space coordinates; Three dimensional space coordinate point (the l of final acquisition series of discrete
i, m
j, k
ij).Finally, directly call extracted coordinate points data, discrete three dimensions point is fitted to a smooth surface, and obtain the space body volume that fitting surface and plane perpendicular project coated, be K value.
This square tube extrusion process common mode intends 177 steps, from 142 steps, wherein enter the extruding seam stabilization sub stage.Now with the 150th step extruding data instance in model, analyze k
ijdistribution value rule.That Fig. 6 represents is bonding point k on seam face
ijbe worth about the diagram of block of bonding point coordinate fitting, curved surface and the plane perpendicular coated volume that projects is K value corresponding to seam path on seam face.Clearly, the k value outside bonding container is more overall than the k value inside bonding container large, and the section bar outboard mass obtained by Splicing Mechanism is better than quality inside section bar.According to calculating, k value is between 1.12 to 7.87, and this value presses the ratio of force and stress to determine by same bonding point.
(5) quantitative Application of welding quality criterion
For the quantitative Application of research seam criterion, extract the data of bonding point on this model extrusion stability stage different step number seam face, and the K value obtaining corresponding step is shown in Fig. 7.Can obtain the K value fluctuation of extrusion stability stage less, under this model, the mean value of K value is 1303.69mm
2, this matches with extruding steady-state process medium section welding quality is basicly stable.
Because not yet someone studies and obtains the seam limit in D extrusion process, calculated numerical value cannot be passed through and directly judge whether that seam is good, but the Dimensionless Form (representing with K*) by obtaining K value judges welding quality quality.Wherein, the average area in seam face is 275.59mm
2, then the mean value K* of all bonding point k values on whole seam face:
This and L.Donati point out well consistent [Donati L, the Tomesani L.The effect of die design on the production and seam weld quality of extrudedaluminum profiles.J Mater Process Tech.2005 of welding quality when the ratio of pressing force and stress is 3 ~ 4 times in the literature; 164:1025-31].
Thus, can be assessed quantitatively section bar D extrusion welding quality exactly by the new method of above-mentioned proposition.
By reference to the accompanying drawings the specific embodiment of the present invention is described although above-mentioned; but not limiting the scope of the invention; one of ordinary skill in the art should be understood that; on the basis of technical scheme of the present invention, those skilled in the art do not need to pay various amendment or distortion that creative work can make still within protection scope of the present invention.
Claims (7)
1. a quantitative evaluating method for Extrusion Process of Aluminum Alloy Profile welding quality, is characterized in that: comprise the following steps:
(1) D extrusion model is created, and model is imported in finite element software, carry out stress and strain model and squeezing parameter setting, numerical simulation is carried out to Extrusion Process of Aluminum Alloy Profile seam process, obtain metal flow and contact seam face from being diverted to, then generating portion seam, then to the material flowing law in the whole extruding seam process of section bar extrusion work strip;
(2) data messages such as the pressure of all bonding points on seam face, stress and three-dimensional coordinate are extracted;
(3) data message of extraction is processed, obtain discrete three dimensional space coordinate point;
(4) three dimensions discrete for gained point is fitted to a smooth surface, and obtain the space body volume that this fitting surface and plane perpendicular project coated, be the K value that seam path on seam face is corresponding.
2. the quantitative evaluating method of a kind of Extrusion Process of Aluminum Alloy Profile welding quality as claimed in claim 1, is characterized in that: in described step (1), specifically comprise:
(1-1) utilize UG to create D extrusion model derive stl file, stl file to be imported in Forge-3D and to carry out stress and strain model and squeezing parameter is arranged;
(1-2) friction kind, coefficient and heat transfer parameter are set according to the kind of mould and the die region of material flowing therethrough.
3. the quantitative evaluating method of a kind of Extrusion Process of Aluminum Alloy Profile welding quality as claimed in claim 1, it is characterized in that: in described step (2), the correlation parameter of all seam nodes on seam face is extracted by the aftertreatment of Forge-3D software, comprise: node pressure p, node stress σ, node flow velocity v and node coordinate (x, y, z).
4. the quantitative evaluating method of a kind of Extrusion Process of Aluminum Alloy Profile welding quality as claimed in claim 1, is characterized in that: in described step (2), the number of bonding point is determined by mesh-density, and stress and strain model is finer and closely woven, and seam nodes is more.
5. the quantitative evaluating method of a kind of Extrusion Process of Aluminum Alloy Profile welding quality as claimed in claim 1, is characterized in that: in described step (3), according to extracted node pressure p, node stress σ, determines that each bonding point k value is: k
ij=p
ij/ σ
ij, i.e. Z axis coordinate in space coordinates.
6. the quantitative evaluating method of a kind of Extrusion Process of Aluminum Alloy Profile welding quality as claimed in claim 1, is characterized in that: in described step (3), according to the actual coordinate (x, y, z) extracting node, converts thereof into seam areal coordinate l
i, m
j, i.e. X, Y-axis coordinate in space coordinates; Three dimensional space coordinate point (the l of final acquisition series of discrete
i, m
j, k
ij).
7. the quantitative evaluating method of a kind of Extrusion Process of Aluminum Alloy Profile welding quality as claimed in claim 1, it is characterized in that: in described step (4), first discrete three dimensions point coordinate data is called, then adopt stress and strain model function to carry out grid data division to XY plane and seam face, whole XY face is divided into the identical surface elemant of size; By difference functions, interpolation is carried out to Z-direction data; With drawing function, the data fitting after interpolation is become smooth surface; Finally by summing function, space body volume corresponding for all surface elemants is added up, K value can be obtained.
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| CN109187187A (en) * | 2018-09-26 | 2019-01-11 | 山东大学 | A method of metal material solid State Welding performance is quantitatively evaluated |
| CN109967545A (en) * | 2019-04-03 | 2019-07-05 | 山东科技大学 | Cross weld and discard method for determining dimension in aluminum profile production process |
| CN112733406A (en) * | 2021-01-20 | 2021-04-30 | 昆山六丰机械工业有限公司 | Method for establishing friction stir welding structure defect prediction model by using finite element method |
| CN117113156A (en) * | 2023-10-20 | 2023-11-24 | 浙江鸿昌铝业有限公司 | Saw cutting section quality analysis method for aluminum profile |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN109187187A (en) * | 2018-09-26 | 2019-01-11 | 山东大学 | A method of metal material solid State Welding performance is quantitatively evaluated |
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