CN111141437A - Method for measuring residual stress in resistance spot welding joint - Google Patents
Method for measuring residual stress in resistance spot welding joint Download PDFInfo
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- CN111141437A CN111141437A CN202010002210.XA CN202010002210A CN111141437A CN 111141437 A CN111141437 A CN 111141437A CN 202010002210 A CN202010002210 A CN 202010002210A CN 111141437 A CN111141437 A CN 111141437A
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- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
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Abstract
The embodiment of the invention provides a method for measuring residual stress in a resistance spot welding joint, which comprises the following steps: splitting a nugget of the resistance spot-welded joint; performing an instrumented indentation experiment on the nugget splitting surface and the peripheral area of the nugget splitting surface, and converting a load-displacement curve generated in the instrumented indentation experiment process into a stress-strain curve; establishing a finite element model in the resistance spot welding process; and carrying out finite element simulation on the resistance spot welding process by using the finite element model and the stress-strain curve to obtain the internal residual stress of the resistance spot welding joint. According to the method for measuring the residual stress in the resistance spot welding joint, provided by the embodiment of the invention, the stress-strain curve of each micro area of the resistance spot welding joint material is obtained through an instrumented indentation experiment, and the accuracy of the residual stress calculation result is improved by adopting a residual stress finite element calculation method considering the actual mechanical property of the material of the micro area.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a method for measuring residual stress in a resistance spot welding joint.
Background
The resistance spot welding technology has the advantages of high efficiency, low cost, high automation degree and the like, and is one of the most widely applied welding methods in the fields of aerospace, automobile manufacturing, rail transit and the like. Resistance spot welding involves the coupling process of electric field, heat transfer, mechanics and metallurgy, and the residual stress generated in the process can have great influence on the mechanical property of the component. Therefore, accurate measurement of residual stress in the spot welding member has guiding significance for service life analysis and prediction of the welding spot.
Due to the characteristics of final solidification of the center of the resistance spot welding nugget and the control requirement of the size of the nugget, the maximum value of spot welding residual stress is often around the nugget in the welding spot. In the prior art, most of the methods for measuring the residual stress in the experiment are surface stress measurement, and the internal stress testing technology is rare and is not suitable for detecting the residual stress in the resistance spot welding joint. Although the neutron diffraction method can measure the internal stress of an object, the measuring equipment is expensive, high in use cost and extremely low in availability.
In recent years, numerical simulation is more and more widely applied in the field of welding, time can be saved and cost can be reduced by calculating welding residual stress by using a numerical simulation method, but because the mechanical properties of micro areas of materials before and after welding are changed, particularly for aluminum alloy materials, if the residual stress is calculated on the basis of the mechanical properties of base materials before welding, a simulation result and an experimental result have a large difference.
Methods exist in the prior art that combine experimentation with numerical simulations. Although the method in the prior art can improve the accuracy of the welding residual stress calculation, the following defects also exist: 1. before the residual stress test is carried out, a processed sample is required to carry out a tensile destructive test on the mechanical property of a joint micro-area, and the micro-area property is difficult to accurately obtain due to the large size requirement of the sample; 2. the processing objects aimed by the method are in a butt joint form, and for resistance spot welding joints, because the size is small, the nuggets are positioned in the central part of the lap joint test plate, and the sampling and stretching method in the prior art is more difficult to realize.
Disclosure of Invention
The embodiment of the invention provides a method for measuring residual stress in a resistance spot welding joint, which is used for solving the defect of inaccurate measurement result of the residual stress in the resistance spot welding joint in the prior art and realizing accurate measurement of the residual stress in the resistance spot welding joint.
The embodiment of the invention provides a method for measuring residual stress in a resistance spot welding joint, which comprises the following steps:
splitting the resistance spot welding joint;
performing an instrumented indentation experiment on the dissected surface of the resistance spot welding joint, and converting a load-displacement curve generated in the instrumented indentation experiment process into a stress-strain curve;
establishing a finite element model in the resistance spot welding process;
and carrying out finite element simulation on the resistance spot welding process by using the finite element model to obtain the internal residual stress of the resistance spot welding joint.
In the above technical solution, after the splitting the resistance spot weld joint, the method further includes:
and grinding, polishing and corroding the split surface of the resistance spot welding joint.
In the above technical solution, the split resistance spot weld joint includes: sectioning the resistance spot weld joint along a cross section at a nugget center of the resistance spot weld joint.
In the above technical solution, the performing an instrumented indentation test includes:
selecting a plurality of instrumented indentation experiment test points in a nugget area of a split surface of the resistance spot welding joint and in an area around the nugget area;
and respectively carrying out press-in experiments on the plurality of instrumented press-in experiment test points to obtain load-displacement curves corresponding to the test points.
In the above technical solution, any one of the following methods is adopted to convert the load-displacement curve generated in the instrumented indentation experiment process into a stress-strain curve: model solution, numerical optimization, and representative strain.
In the above technical solution, the instrumented indentation experiment is as follows: nano-indentation experiments or micro-indentation experiments or millimeter indentation experiments.
In the above technical solution, the establishing a finite element model in the resistance spot welding process includes:
performing geometric reconstruction on the resistance spot welding joint, and establishing a resistance spot welding joint geometric model containing a nugget shape;
meshing the geometric model;
material properties are assigned to each mesh in the geometric model.
In the above technical solution, the meshing the geometric model includes:
and refining the grids of the nugget area, so that the side length of the grids of the nugget area is smaller than that of the grids of other areas except the nugget area in the resistance spot welding joint.
In the above technical solution, the performing finite element simulation on the resistance spot welding process by using the finite element model and the stress-strain curve includes:
determining technological parameters adopted in the finite element simulation process according to the actual spot welding process;
and simulating the resistance spot welding process by using the finite element model, wherein the mechanical property before the nugget is solidified adopts the existing stress-strain curve of the base material, and the room-temperature mechanical property after the nugget is solidified adopts the first stress-strain curve.
In the above technical solution, the process parameters at least include: electrode diameter, welding current magnitude, electrode pressure and welding time.
According to the method for measuring the residual stress in the resistance spot welding joint, provided by the embodiment of the invention, the stress-strain curve of each micro area of the resistance spot welding joint material is obtained through an instrumented indentation experiment, and the accuracy of the residual stress calculation result is improved by adopting a residual stress finite element calculation method considering the actual mechanical property of the material of the micro area.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and those skilled in the art can also obtain other drawings according to the drawings without creative efforts.
Fig. 1 is a flowchart of a method for measuring residual stress inside a resistance spot welding joint according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of the positions of a resistance spot welding nugget metallographic phase and an instrumented indentation test point;
FIG. 3 is a flow chart of a method for measuring residual stress within a resistance spot weld joint according to another embodiment of the present invention;
FIG. 4 is a graph of load versus displacement from a plunge test conducted in accordance with an embodiment of the invention;
FIG. 5 is a graph of stress-strain curves obtained after conversion of the load-displacement curves shown in FIG. 4;
fig. 6 is a comparison graph of the residual stress distribution of the upper surface of the resistance spot welding nugget measured by the full release method according to one embodiment of the present invention and the calculation results obtained by the method for measuring the internal residual stress of the resistance spot welding joint according to the embodiment of the present invention;
FIG. 7 is a graph comparing the distribution of the residual stress on the upper surface of the resistance spot welding nugget measured by the full release method with the calculated results obtained by the prior art residual stress measuring method without taking the mechanical properties of the micro-zones into consideration in the same example of the present invention as in FIG. 6;
FIG. 8 is a graph comparing the residual stress distribution of the upper surface of the resistance spot welding nugget measured by the full release method according to another embodiment of the present invention with the calculated results obtained by the method for measuring the internal residual stress of the resistance spot welding joint according to the embodiment of the present invention;
fig. 9 is a graph comparing the distribution of the residual stress on the upper surface of the resistance spot welding nugget measured by the full release method with the calculation result obtained by the prior art residual stress measuring method without considering the micro-area mechanical properties in the same example of the present invention as in fig. 8.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Fig. 1 is a flowchart of a method for measuring residual stress inside a resistance spot welding joint according to an embodiment of the present invention, and as shown in fig. 1, the method for measuring residual stress inside a resistance spot welding joint according to an embodiment of the present invention includes:
and step 101, splitting the resistance spot welding joint.
In the embodiment of the present invention, it is preferable to cut the resistance spot weld joint along a cross section from the center of the nugget. Since the residual stress at the nugget center of the resistance spot weld joint is generally the greatest, sectioning from the nugget center further facilitates detection of the true value of the residual stress within the resistance spot weld joint. In other embodiments, the dissection is performed with a certain degree of deviation from the nugget center, such as 0.5mm apart, within the tolerance allowed.
102, performing an instrumented indentation experiment on the sectioning surface of the resistance spot welding joint, and converting a load-displacement curve generated in the instrumented indentation experiment process into a stress-strain curve.
Inside the resistance spot weld joint, there are differences in material properties and temperature fields in different areas, and therefore it is necessary to detect the stress in different areas inside the resistance spot weld joint. The stress of different areas is detected, and a plurality of instrumented indentation experiment test points are selected from different areas in the resistance spot welding joint to obtain corresponding mechanical properties. Generally, the interior of the resistance spot weld joint may be divided into a nugget region, a base material region, and an interface region at the interface between the nugget and the base material. Since the residual stress of the resistance spot welded joint is mainly concentrated in and around the nugget area, in the embodiment of the invention, the selected test point is mainly located in and around the nugget area. The test points are spaced apart (e.g., 0.5mm) to reflect stress distribution within the resistance spot weld joint in various areas, particularly the nugget region and the vicinity of the nugget region. Fig. 2 is a schematic diagram of the positions of the metallographic phase of the resistance spot welding nugget and the instrumented indentation test points, and the positions of 6 test points are exemplarily marked in fig. 2.
After test points are selected for the instrumented indentation experiment, the indentation experiment is respectively carried out on each test point, and each test point can generate a respective load-displacement curve. And the representative strain method can be adopted to convert the load-displacement curve of each test point into the stress-strain curve of the material in the area corresponding to the test point. How to convert a load-displacement curve into a stress-strain curve by a representative strain method is well known to those skilled in the art, and the conversion process is not described in detail herein. The method for converting the load-displacement curve into the stress-strain curve is not limited to the representative strain method involved in the embodiment of the present invention, and in other embodiments of the present invention, methods such as a model solution method, a numerical optimization method, and the like may also be employed.
The diameter of the spherical pressure head adopted in the instrumented indentation experiment in the step is 0.5mm, and the spherical pressure head belongs to a millimeter indentation experiment.
And 103, establishing a finite element model in the resistance spot welding process.
In the embodiment of the invention, when the finite element model is established for the resistance spot welding process, firstly, the geometric reconstruction is carried out on the resistance spot welding joint, and the geometric model of the resistance spot welding joint containing the nugget shape is established; the geometric model at least comprises the information of the shape, the size and the like of the nugget area.
The geometric model is then gridded and constraints are applied. In the embodiment of the invention, the grid is divided by using the eight-node linear hexahedron reduction integral unit, and the side length of the average grid is 0.5-1 mm. As a preferred implementation mode, the grids in the nugget area can be further refined, and the side length of the minimum grid is 0.1-0.05 mm. Constraints are imposed on the geometric model to ensure that the model does not rotate or translate during the calculation process.
After each grid is obtained, material properties are given to the grids according to the material types of the areas corresponding to the grids. The material properties include modulus of elasticity, poisson's ratio, density, yield strength, thermal conductivity, and the like.
And 104, performing finite element simulation on the resistance spot welding process by using a finite element model to obtain the internal residual stress of the resistance spot welding joint.
The steps further include:
determining technological parameters adopted in the finite element simulation process according to the actual spot welding process; these process parameters include at least: electrode diameter, welding current, electrode pressure and welding time;
and simulating the resistance spot welding process by using the finite element model, wherein the mechanical property before the nugget is solidified adopts the existing stress-strain curve of the base material, and the room-temperature mechanical property after the nugget is solidified adopts the stress-strain curve obtained by instrumental pressing, namely the stress-strain curve of the material in the region corresponding to the test point obtained in the step 102 is used.
The residual stress magnitude and distribution condition of each area in the resistance spot welding joint, particularly near the nugget, can be finally obtained through finite element simulation.
According to the method for measuring the residual stress in the resistance spot welding joint, provided by the embodiment of the invention, the stress-strain curve of each micro area of the resistance spot welding joint material is obtained through an instrumented indentation experiment, and the accuracy of the residual stress calculation result is improved by adopting a residual stress finite element calculation method considering the actual mechanical property of the material of the micro area.
Based on any one of the above embodiments, fig. 3 is a flowchart of a method for measuring residual stress inside a resistance spot welding joint according to another embodiment of the present invention, and as shown in fig. 3, the method for measuring residual stress inside a resistance spot welding joint according to another embodiment of the present invention includes:
in the step, the split surfaces of the resistance spot welding joints are ground, polished and corroded, so that the nugget boundaries can be distinguished, and the accuracy of instrumental pressing is improved.
and 305, performing finite element simulation on the resistance spot welding process by using a finite element model to obtain the internal residual stress of the resistance spot welding joint.
The method for measuring the residual stress in the resistance spot welding joint provided by the embodiment of the invention is beneficial to distinguishing the nugget boundary and improving the accuracy of instrumented indentation by grinding, polishing and corroding the split surface of the resistance spot welding joint.
In another embodiment of the invention, taking a 5083-H112 aluminum alloy resistance spot welding joint with the combination of 6+4mm as an example, the residual stress evaluation is carried out by adopting the method for calculating the internal residual stress of the resistance spot welding joint provided by the embodiment of the invention, and the related steps are as follows:
1) the resistance spot welding joint is cut from the center of the nugget by a wire cutting method, and is ground, polished and corroded. A spherical indenter with the diameter of 0.5mm is adopted to carry out indentation experiments on the corroded test piece, the position of a test point in the indentation experiment can be shown in fig. 2, a load-displacement curve shown in fig. 4 is obtained, the load-displacement curve of each indentation point is converted into a stress-strain curve of the material by a representative strain method, and the obtained stress-strain curve is shown in fig. 5.
2) And establishing a finite element model in the resistance spot welding process, wherein a dynamically refined grid is used in a nugget area, and the minimum grid size is 0.05 mm. The finite element simulation process parameters are determined by referring to an actual spot welding process: electrode diameter 15mm, welding current 19kA, electrode pressure 10kN, welding time 100 ms. The mechanical property before the solidification of the nuggets adopts the existing stress-strain curve of the base material, and the room-temperature mechanical property after the solidification of the nuggets adopts the stress-strain curve of the corresponding micro-area material. And calculating by using the finite element model to obtain a radial residual stress distribution cloud chart and a tangential residual stress distribution cloud chart of the nugget.
In order to verify the accuracy of the simulation result, the residual stress distribution of the upper surface of the resistance spot welding nugget is measured by using a full release method, fig. 6 is a comparison graph of the residual stress distribution (abbreviated as an experimental result) of the upper surface of the resistance spot welding nugget measured by using the full release method and a surface calculation result (abbreviated as a simulation result) obtained by using the method for measuring the residual stress inside the resistance spot welding joint provided by the embodiment of the invention, and it can be seen from the graph that the experimental result is consistent with the simulation result. Fig. 7 is a comparison graph of the residual stress distribution (abbreviated as experimental result) of the upper surface of the resistance spot welding nugget measured by the total release method and a calculation result (abbreviated as simulation result) obtained by the residual stress measurement method in the prior art without considering the mechanical property of the micro-area, and it can be seen from the graph that the difference between the experimental result and the simulation result is large. The method for measuring the residual stress in the resistance spot welding joint is proved to be improved in accuracy of a residual stress calculation result compared with the method in the prior art.
In another embodiment of the present invention, taking a 6N01-T5 aluminum alloy resistance spot welding joint with a combination of 6+4mm as an example, the method for measuring the internal residual stress of the resistance spot welding joint provided by the embodiment of the present invention is adopted to calculate the residual stress, and the related steps are as follows:
1) and splitting the resistance spot welding joint from the center of the nugget by using a wire cutting method, and grinding, polishing and corroding the resistance spot welding joint. And (3) carrying out a pressing-in experiment on the corroded test piece by adopting a spherical pressure head with the diameter of 0.5mm to obtain a load-displacement curve, and converting the load-displacement curve of each pressing-in point into a stress-strain curve of the material by using a representative strain method.
2) And establishing a finite element model in the resistance spot welding process, wherein a dynamically refined grid is used in a nugget area, and the minimum grid size is 0.05 mm. The finite element simulation process parameters are determined by referring to an actual spot welding process: electrode diameter 15mm, welding current 16kA, electrode pressure 9kN, and welding time 80 ms. The mechanical property before the solidification of the nuggets adopts the existing stress-strain curve of the base material, and the room-temperature mechanical property after the solidification of the nuggets adopts the stress-strain curve of the corresponding micro-area material. And calculating by using the finite element model to obtain a radial residual stress distribution cloud chart and a tangential residual stress distribution cloud chart of the nugget.
In order to verify the accuracy of the simulation result, the residual stress distribution of the upper surface of the resistance spot welding nugget is measured by using the full-release method, fig. 8 is a comparison graph of the residual stress distribution (abbreviated as an experimental result) of the upper surface of the resistance spot welding nugget measured by using the full-release method and a surface calculation result (abbreviated as a simulation result) obtained by using the method for measuring the residual stress inside the resistance spot welding joint provided by the embodiment of the invention, and it can be seen from the graph that the experimental result is consistent with the simulation result. Fig. 9 is a comparison graph of the residual stress distribution (abbreviated as experimental result) of the upper surface of the resistance spot welding nugget measured by the total release method and the calculated result (abbreviated as simulation result) obtained by the residual stress measurement method without considering the mechanical property of the micro-area in the prior art, and it can be seen from the graph that the difference between the experimental result and the simulation result is large. Fig. 8 and 9 also demonstrate that the residual stress measuring method in the resistance spot welding joint provided by the embodiment of the invention is improved in the accuracy of the residual stress calculation result compared with the method in the prior art.
The above-described embodiments of the apparatus are merely illustrative, and the units described as separate parts may or may not be physically separate, and parts displayed as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of network units. Some or all of the modules may be selected according to actual needs to achieve the purpose of the solution of the present embodiment. One of ordinary skill in the art can understand and implement it without inventive effort.
Through the above description of the embodiments, those skilled in the art will clearly understand that each embodiment can be implemented by software plus a necessary general hardware platform, and certainly can also be implemented by hardware. With this understanding in mind, the above-described technical solutions may be embodied in the form of a software product, which can be stored in a computer-readable storage medium such as ROM/RAM, magnetic disk, optical disk, etc., and includes instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) to execute the methods described in the embodiments or some parts of the embodiments.
Finally, it should be noted that: the above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.
Claims (10)
1. A method for measuring residual stress inside a resistance spot welding joint is characterized by comprising the following steps:
splitting the resistance spot welding joint;
performing an instrumented indentation experiment on the dissected surface of the resistance spot welding joint, and converting a load-displacement curve generated in the instrumented indentation experiment process into a stress-strain curve;
establishing a finite element model in the resistance spot welding process;
and carrying out finite element simulation on the resistance spot welding process by using the finite element model and the stress-strain curve to obtain the internal residual stress of the resistance spot welding joint.
2. The method of measuring residual stress within a resistance spot weld joint according to claim 1, wherein after severing the resistance spot weld joint, the method further comprises:
and grinding, polishing and corroding the split surface of the resistance spot welding joint.
3. A resistance spot weld joint internal residual stress measurement method according to claim 1 or 2, characterized in that the sectioning of the resistance spot weld joint comprises: sectioning the resistance spot weld joint along a cross section at a nugget center of the resistance spot weld joint.
4. The method of measuring residual stress inside a resistance spot weld joint according to claim 1 or 2, wherein performing an instrumented indentation test on a sectioned surface of the resistance spot weld joint comprises:
selecting a plurality of instrumented indentation experiment test points in a nugget area of a split surface of the resistance spot welding joint and in an area around the nugget area;
and respectively carrying out press-in experiments on the plurality of instrumented press-in experiment test points to obtain load-displacement curves corresponding to the test points.
5. The method for measuring residual stress inside a resistance spot weld joint according to claim 1 or 2, wherein the load-displacement curve generated during the instrumented indentation test is converted into a stress-strain curve by any one of the following methods: model solution, numerical optimization, and representative strain.
6. The method for measuring residual stress inside a resistance spot weld joint according to claim 1 or 2, wherein the instrumented indentation test is: nano-indentation experiments or micro-indentation experiments or millimeter indentation experiments.
7. The method of measuring residual stress inside a resistance spot weld joint according to claim 1 or 2, wherein said establishing a finite element model of a resistance spot welding process comprises:
performing geometric reconstruction on the resistance spot welding joint, and establishing a resistance spot welding joint geometric model containing a nugget shape;
meshing the geometric model;
material properties are assigned to each mesh in the geometric model.
8. The method of measuring residual stress inside a resistance spot weld joint according to claim 7, wherein said meshing said geometric model comprises:
and refining the grids of the nugget area, so that the side length of the grids of the nugget area is smaller than that of the grids of other areas except the nugget area in the resistance spot welding joint.
9. The method of measuring residual stress inside a resistance spot weld joint according to claim 1 or 2, wherein the performing a finite element simulation of a resistance spot welding process using the finite element model and the stress-strain curve comprises:
determining technological parameters adopted in the finite element simulation process according to the actual spot welding process;
and simulating the resistance spot welding process by using the finite element model, wherein the mechanical property before the solidification of the nugget adopts the existing stress-strain curve of the base material, and the room-temperature mechanical property after the solidification of the nugget adopts the stress-strain curve obtained by instrumental pressing.
10. Method for measuring residual stresses inside a resistance spot weld joint according to claim 1 or 2, characterized in that said process parameters comprise at least: electrode diameter, welding current magnitude, electrode pressure and welding time.
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