CN108672893B - Control method for penetration form and penetration depth of asymmetric fillet weld - Google Patents

Control method for penetration form and penetration depth of asymmetric fillet weld Download PDF

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CN108672893B
CN108672893B CN201810488858.5A CN201810488858A CN108672893B CN 108672893 B CN108672893 B CN 108672893B CN 201810488858 A CN201810488858 A CN 201810488858A CN 108672893 B CN108672893 B CN 108672893B
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molten pool
penetration
welding
fillet weld
temperature
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CN108672893A (en
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岳建锋
李亮玉
常玉烁
许凯
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Tianjin Polytechnic University
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/095—Monitoring or automatic control of welding parameters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode

Abstract

The invention discloses a method for controlling penetration form and penetration depth of an asymmetric fillet weld, belonging to the field of welding automation, the invention provides a method for controlling the shape of a molten pool by adjusting the angle of a welding gun to control the penetration forming of an asymmetric fillet weld and identifying a front molten pool model based on a visual method to realize the estimation and control of penetration depth, the heat dissipation difference of two side plates of an asymmetric structure is large, and the penetration forming of two sides is difficult to control. The penetration forming control of the asymmetric fillet weld is realized, and the difficult problem of improving the welding quality of the special structure is solved.

Description

Control method for penetration form and penetration depth of asymmetric fillet weld
Technical Field
The invention belongs to the field of welding automation, and mainly relates to a method for controlling the penetration form and penetration depth of an asymmetric fillet weld, namely a method for respectively controlling the form and the penetration depth of a molten pool to ensure the welding quality of the asymmetric fillet weld. The method specifically comprises the steps of influencing the form of a molten pool at a welding seam by changing the angle of a welding gun, estimating the penetration depth by a three-dimensional temperature field analytic model corrected by front molten pool image information, and combining the three-dimensional temperature field analytic model and the front molten pool image information to realize penetration forming control.
Background
At present, a plurality of asymmetric fillet welds with different thicknesses exist at parts such as an airplane body, an engine container and the like, the heat dissipation conditions of the welds and the symmetric welds are obviously different, the penetration formation of welding is influenced, and especially the backing welding of the root with the most prominent structure becomes a key for restricting the quality of the whole welding joint. The main problems of such structures in welding are: (1) the thick plate side is easy to generate non-fusion defects. Due to the asymmetric structure of the fillet weld (the thickness of the truncated edge is generally 1-2mm, and the thickness of the thick plate on the other side is more than 5mm, as shown in fig. 1), the penetration depth of the welded plate on the side of the groove under the same heat input condition is large, and the penetration depth is relatively shallow due to the large heat dissipation coefficient of the thick plate side, so that the deviation between the penetration center direction and the longitudinal direction of the groove is caused, and the non-fusion defect is easily generated. (2) Poor fusion stability and poor forming. The thickness difference of base materials on two sides of the asymmetric fillet weld is large, and the difference from the structure of the symmetric weld makes the penetration forming quality in the asymmetric fillet weld influenced by external random interference more sensitive, so that the phenomenon of unstable penetration forming often occurs, and the performance of the final welded product is greatly reduced. Therefore, to solve the above problems, it is very important to realize the automatic welding under such working conditions.
A great deal of research is carried out at home and abroad in recent years aiming at the problem of penetration control of welding seams, as penetration does not have the characteristic of direct measurement, the center of gravity and the difficulty of the current research are to seek to establish the relationship between sensing information and penetration characteristics, the visual sensing information amount is large when various kinds of penetration sensing information are integrated, the front molten pool image is convenient to acquire, the front molten pool image is combined with the temperature information rich in the boundary position of the molten pool image, the precision of a temperature field model can be improved, and the penetration control of asymmetric fillet welding seams can be realized by means of methods such as online calculation of penetration depth information by means of the corrected model and the like.
Disclosure of Invention
The invention aims to provide a method for controlling the penetration form and penetration depth of an asymmetric fillet weld, which solves the problem of the relation between the front molten pool form and penetration forming and can be effectively applied to the aspect of penetration quality control of asymmetric fillet weld. The invention realizes real-time penetration control by a method combining the control of the internal molten pool form by the welding gun angle and the solution of the penetration depth by the established and improved three-dimensional temperature field analytical model.
In order to solve the technical problems, the invention adopts the technical scheme that: a method for controlling the penetration form and the penetration depth of an asymmetric fillet weld comprises the following steps:
step (1) asymmetric fillet weld welding, wherein the influence rule of different welding gun angles on the shape of a molten pool at the welding seam is obtained through an experiment and finite element simulation method, the welding gun angle range suitable for full penetration of the welding seam is determined, and the shape of the molten pool is controlled by changing the welding gun angle in the range;
because the angle change of a welding gun changes the heat input at the two sides of the fillet weld in the welding process, the melting amount of parent metal in different directions of the fillet weld is different, the shape of a molten pool is changed, the included angle between the welding gun and one side of a thick plate is selected from 15-45 degrees to carry out a welding test, cutting, grinding, polishing, corroding and other operations are carried out on a workpiece, the workpiece is placed under a microscope to take a picture, and the obtained result is compared with the simulated change rule of the shape of the molten pool;
step (2) combining a finite element simulation rule of asymmetric angle root welding seam penetration forming, deducing a temperature field analytical model of the angle root welding seam workpiece with a limited size, developing a welding test optimization model, and improving the precision;
the equation of the temperature field of the point heat source in the infinite body is as follows:
Figure GDA0002337400790000021
but of limited sizefinSolving is very difficult, so the heat source is equivalent according to the principle of energy conservation, and the temperature field model is expressed as follows:
Figure GDA0002337400790000022
the Gaussian heat source suitable for the asymmetric fillet weld is selected to reverse the equivalent heat source under the condition of a workpiece with a limited size as follows:
Figure GDA0002337400790000023
substituting (3) into (2) further derives the equivalent temperature field for a finite size workpiece in a fixed coordinate system of length L, width B, and thickness D:
Figure GDA0002337400790000031
wherein
Figure GDA0002337400790000032
Figure GDA0002337400790000033
Figure GDA0002337400790000034
Figure GDA0002337400790000035
Thus, an asymmetric fillet weld overall temperature field is obtained according to the principle of superposition and the graph of FIG. 8
T(x,y,z,t)＝T1(x,y,z,t)+T2(x,y,z,t)-T0(9)
In the formula: t is1(x, y, z, T) is the vertical temperature field, T2(x, y, z, T) is the temperature field of the soleplate, T0The initial temperature of the workpiece, namely room temperature;
acquiring a front molten pool image by using a camera to acquire position information of a boundary melting point temperature of a molten pool;
collecting a molten pool image in a welding basic value current stage, extracting a clearer molten pool edge through filtering, image enhancement and image segmentation, wherein the molten pool edge is a solid-liquid boundary, the temperature of the position can be regarded as the melting point temperature of a metal material, obtaining the geometric edge profile of the molten pool and the position coordinates of a tungsten pole in the molten pool image through image processing, and obtaining the limit end point coordinates of the left side and the right side and the limit end point coordinates of the front end.
And (4) identifying and analyzing the heat source parameters of the model by using the temperature coordinates, and solving the maximum melting point temperature coordinate by using the corrected model to realize the online calculation and solution of the penetration depth.
In order to complete the online identification of two Gaussian heat source distribution parameters sigma of the side plate and the groove bottom plate, a target optimization function E related to the melting point temperature is defined by using a least square method as follows:
Figure GDA0002337400790000041
in the formula: t isi *Measuring the temperature of the characteristic point of the edge of the molten pool, corresponding to the melting point temperature; t isiCalculating a temperature measuring point; and m is the number of temperature measuring points.
And when the objective function E is minimum, obtaining the optimal value of the Gaussian heat source distribution parameter sigma.
And (5) automatically changing the angle of the welding gun and heat input parameters (voltage and current) under feedback regulation, and realizing the real-time control of the asymmetric angle welding.
The adopted welding test conditions are that a wire-filling TIG welding method is adopted, the power frequency is 2Hz, the test material is Q235, the welding speed is 3mm/s, the protective gas is Ar, the size of an unbundled groove plate is 170mm multiplied by 50mm multiplied by 6mm, the size of a divided groove plate is 170mm multiplied by 50mm multiplied by 6mm (a groove with 60 degrees and a truncated edge with 2 mm), the angle β of a welding gun is determined as the actual included angle between the welding gun and one side of a thick plate, and the test is carried out on the β value of 15-45 degrees.
The vision sensing system employed comprises: an XVC-G type CCD camera produced by Xiris in Canada, an image acquisition card and a narrow-band optical filter with the center wavelength of 650mm, and the acquired image is directly transmitted to a computer through an electric injector. The acquired images are subjected to a series of processing by matlab.
By adopting the technical scheme, on one hand, the welding gun angle suitable for welding the asymmetric fillet weld can be found, so that the weld is completely coated by a molten pool, and the defect of incomplete fusion is avoided. On the other hand, the on-line solution of the penetration depth is realized through the three-dimensional temperature field analytic model, and the control of the penetration depth can be realized by changing the heat input, namely the voltage and current parameters of the electric welding machine through feedback regulation. The two aspects are combined, so that the problem that the asymmetric fillet weld is difficult to realize automatic welding can be solved.
The innovation of the invention is that: 1. the different penetration conditions of two side plates of a given heat input are found that the molten pool shape can be influenced by changing the heat distribution of two sides, so that the idea of changing the angle of a welding gun to control the inner molten pool shape is provided. 2. A Gaussian surface heat source is selected on the basis of an equivalent heat source method, a three-dimensional temperature field analytical model on a workpiece with a limited size is deduced, and respective temperature fields of two side plates are further superposed to successfully obtain an integral temperature field analytical model for the fillet weld with the asymmetric structure. 3. The temperature of the edge of the molten pool image is found to be the melting point of the base material, so that the characteristic points are taken on the edge, and the position coordinate information can correct the temperature field analysis model, thereby achieving the purpose of improving the calculation precision of the model penetration depth.
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The advantages and realisation of the invention will be more apparent from the following detailed description, given by way of example, with reference to the accompanying drawings, which are given for the purpose of illustration only, and which are not to be construed in any way as limiting the invention, and in which:
FIG. 1 is a schematic view of an asymmetric fillet weld of the present invention. The problems that the shape of a molten pool is not easy to control and the condition of incomplete fusion or welding leakage at a truncated edge part is easy to occur frequently occur in the welding process of the asymmetric fillet weld, so that the welding quality is influenced.
FIG. 2 is a schematic diagram of the system of the experimental apparatus of the present invention. The beveling plate is simplified into a thin plate, the welding gun is perpendicular to the horizontal plane, the two side plates are placed on the welding frame in an angle of 90 degrees, and the angle between the movable welding gun and the thick plate can be adjusted.
FIG. 3 is a schematic diagram of the experimental apparatus of the present invention.
FIG. 4 is a schematic representation of the effect of the angle of the weld gun of the present invention on the weld puddle morphology at the weld as the angle α of the weld gun changes.
Fig. 5 shows the change rule of the central line of the molten pool along with the angle of the welding gun obtained by the experiment of the invention, wherein β is 15 degrees and β is the included angle between the welding gun and one side of the thick plate, and the experiment shows that the central line of the molten pool also rotates clockwise along with β increasing, which accords with the change rule of the molten pool shape shown in the schematic diagram of fig. 4.
Fig. 6 shows a diagram β of the change of the center line of the molten pool with the angle of the welding gun, which is obtained by the experiment of the invention, is 30 degrees.
Fig. 7 shows the change rule β of the central line of the molten pool along with the angle of the welding gun, which is obtained by the experiment of the invention, is 45 degrees.
FIG. 8 is a fillet weld vertical side plate heat source and beveled bottom plate heat source coordinate system of the present invention, where L1Is long and thick plate B1Is a thick plate width D1Is thick, L2Is a thin plate long, B2Is the width of the sheet D2The thickness of the sheet is small.
Fig. 9 is a molten pool image taken by a CCD camera.
FIG. 10 shows the tungsten needle and the edge of the molten pool after image processing.
FIG. 11 is a schematic view of characteristic points of the edge of the molten pool.
FIG. 12 is a diagram of an asymmetric fillet weld penetration control system.
In the figure:
1. arc 2, molten pool 3, blunt edge
4. Welding gun 5, thin plate 6 and thick plate
7. CCD camera 8, electric power injector 9, computer
Detailed Description
The invention will be further described with reference to the following examples and figures:
as shown in figures 1 to 12 of the drawings,
a visual sensing system: the device consists of an XVC-G type CCD camera produced by Xiris in Canada, an image acquisition card and a narrow-band filter with the center wavelength of 650 mm. The acquired images are transmitted directly to a computer via a power injector. The acquired images are subjected to a series of processing by matlab.
The test conditions are that an epoch TDW4000 pulse TIG welding machine is used in an asymmetric fillet weld welding test, a wire-filling TIG welding method is adopted, the power supply frequency is 2Hz, the test material is Q235, the welding speed is 3mm/s, the protective gas is Ar, the dimension of an unbundled groove plate is 170mm multiplied by 50mm multiplied by 6mm, the dimension of a divided groove plate is 170mm multiplied by 50mm multiplied by 6mm (a groove of 60 degrees and a truncated edge of 2 mm), the welding gun angle β is determined as the actual included angle between a welding gun and one side of a thick plate, and the test is carried out on the β value of 15 degrees to 45 degrees.
The specific implementation process is as follows:
and (1) obtaining the influence rule of different welding gun angles on the form of a molten pool at a welding seam by using an experiment and finite element simulation method. Finding out the angle range of the welding gun suitable for full penetration of the welding seam, and controlling the shape of the molten pool by changing the angle of the welding gun in the range.
As shown in FIG. 4, the welding gun angle changes in the welding process, so that the melting amount of the base metal in different directions of the fillet is different, the molten pool shape changes, the β values are respectively taken as 15 degrees, 30 degrees and 45 degrees to carry out welding tests, the welding piece is cut, ground, polished and corroded, and the like, and the welding piece is photographed under a microscope as shown in FIGS. 5 to 7.
And (2) combining a finite element simulation rule of asymmetric angle root welding seam penetration forming, deducing a temperature field analytical model of the angle root welding seam workpiece with a limited size, developing a welding test optimization model, and improving the precision.
The temperature field equation of a point heat source in an infinite body is that on a workpiece with a finite size
But of limited sizefinSolving is very difficult, so the heat source is equivalent according to the principle of energy conservation, and the temperature field model is expressed as
Figure GDA0002337400790000062
The Gaussian heat source suitable for the asymmetric fillet weld is selected to be used for reversing the equivalent heat source of the asymmetric fillet weld under the condition of a workpiece with a limited size
Figure GDA0002337400790000071
Further generalizing the equation (3) into equation (2) yields an equivalent temperature field for a finite size workpiece in a fixed coordinate system having a length L, a width B, and a thickness D
Figure GDA0002337400790000072
Wherein
Figure GDA0002337400790000073
Figure GDA0002337400790000074
Figure GDA0002337400790000075
Figure GDA0002337400790000076
Thus, an asymmetric fillet weld overall temperature field is obtained according to the principle of superposition and the graph of FIG. 8
T(x,y,z,t)＝T1(x,y,z,t)+T2(x,y,z,t)-T0(9)
And (3) acquiring a front molten pool image by using a camera, and acquiring position information of the boundary melting point temperature of the molten pool.
And collecting a molten pool image at the welding base value current stage, and extracting a clearer molten pool edge through filtering, image enhancement and image segmentation. The edge of the molten pool is a solid-liquid boundary, and the temperature of the position can be regarded as the melting point temperature of the metal material. As shown in FIG. 11, the geometric edge profile of the molten pool and the position coordinate P of the tungsten electrode in the molten pool image are obtained through image processing4And the coordinates P of the limit end points on the left side and the right side can be obtained2,P3And front end limit end point coordinates P1。
And (4) identifying and analyzing the heat source parameters of the model by using the temperature characteristic point coordinates, and solving the maximum melting point temperature coordinate by using the corrected model to realize the online calculation and solution of the penetration depth.
In order to complete the online identification of two Gaussian heat source distribution parameters sigma of the side plate and the groove bottom plate, a target optimization function E related to the melting point temperature is defined by using a least square method as follows:
Figure GDA0002337400790000081
in the formula: t isi *Measured temperature for characteristic points of the edge of the bath, correspondingMelting point temperature; t isiCalculating a temperature measuring point; and m is the number of temperature measuring points.
And when the objective function E is minimum, obtaining the optimal value of the Gaussian heat source distribution parameter sigma.
And (5) automatically changing the angle of the welding gun and heat input parameters (voltage and current) under feedback regulation, and realizing the real-time control of the asymmetric angle welding.
An asymmetric fillet weld penetration control system based entirely on energy distribution and heat input control is shown in FIG. 8. The method comprises the steps that a camera collects molten pool images in real time in the welding process, when the deviation of a welding gun relative to the position of a molten pool or the central line of the molten pool exceeds a reasonable range, the welding gun images are fed back to an automatic welding device to adjust the angle of the welding gun, so that the welding gun images are restored to a normal molten pool shape, the heat input parameters are brought into a temperature field analysis model, the on-line solving penetration depth is not larger than or larger than a target depth, namely when full penetration or possible welding leakage is not achieved, the parameters such as welding current and the like are fed back to the automatic welding device to adjust, and.
The embodiments of the present invention have been described in detail, but the description is only for the preferred embodiments of the present invention and should not be construed as limiting the scope of the present invention. All equivalent changes and modifications made within the scope of the present invention should be covered by the present patent.

Claims (5)

1. A method for controlling the penetration form and the penetration depth of an asymmetric fillet weld is characterized by comprising the following steps: the method comprises the following steps:
step (1) asymmetric fillet weld welding, wherein the influence rule of different welding gun angles on the shape of a molten pool at the welding seam is obtained through an experiment and finite element simulation method, the welding gun angle range suitable for full penetration of the welding seam is determined, and the shape of the molten pool is controlled by changing the welding gun angle in the range;
step (2) combining a finite element simulation rule of asymmetric angle root welding seam penetration forming, deducing a temperature field analytical model of the angle root welding seam workpiece with a limited size, developing a welding test optimization model, and improving the precision;
the integral temperature field formula of the asymmetric fillet weld is as follows:
T(x,y,z,t)＝T1(x,y,z,t)+T2(x,y,z,t)-T0
in the formula: t is1(x, y, z, T) is the vertical temperature field, T2(x, y, z, T) is the temperature field of the soleplate, T0Is the initial temperature of the workpiece;
acquiring a front molten pool image by using a visual sensing system, and acquiring position information of a boundary melting point temperature of a molten pool;
step (4) identifying and analyzing model heat source parameters by using temperature coordinates, and solving the maximum melting point temperature coordinate by using the corrected model to realize online calculation and solution of penetration depth;
and (5) automatically changing the angle of the welding gun and the heat input parameter under the feedback regulation, and realizing the real-time control of the welding of the asymmetric fillet weld.
2. The method for controlling the penetration form and penetration depth of the asymmetric fillet weld according to claim 1, which is characterized in that: and (2) selecting an included angle between the welding gun and one side of the thick plate in the step (1) to perform a welding test, performing cutting, grinding, polishing and corrosion operations on the workpiece, taking a picture under a microscope, and comparing the obtained result with the simulated change rule of the molten pool form.
3. The method for controlling the penetration form and penetration depth of the asymmetric fillet weld according to claim 1, which is characterized in that: in the step (3), a molten pool image is collected at a welding basic value current stage, the edge of the molten pool is extracted through filtering, image enhancement and image segmentation, the edge of the molten pool is a solid-liquid boundary, the temperature of the position can be regarded as the melting point temperature of a metal material, the geometric edge profile of the molten pool and the position coordinates of a tungsten electrode in the molten pool image are obtained through image processing, and the limit end point coordinates of the left side and the right side and the limit end point coordinate of the front end are obtained.
4. The method for controlling the penetration form and penetration depth of the asymmetric fillet weld according to claim 1, which is characterized in that: in the step (4), in order to complete the online identification of two Gaussian heat source distribution parameters sigma of the side plate and the beveled bottom plate, a target optimization function E related to the melting point temperature is defined by using a least square method as follows:
Figure FDA0002337400780000021
in the formula: t isi *Measuring the temperature of the characteristic point of the edge of the molten pool, corresponding to the melting point temperature; t isiCalculating a temperature measuring point; and m is the number of temperature measuring points, and when the objective function E is minimum, the optimal value of the Gaussian heat source distribution parameter sigma is obtained.
5. The method for controlling the penetration form and penetration depth of the asymmetric fillet weld according to claim 1, which is characterized in that: the method adopts a vision sensing system comprising the following steps: the CCD camera, the image acquisition card and the narrow-band optical filter with the center wavelength of 650mm, the acquired image is directly transmitted to the computer through the power injector, and the acquired image is processed by matlab.
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