CN111767666B - CAE simulation method for laser welding connection of automobile parts - Google Patents
CAE simulation method for laser welding connection of automobile parts Download PDFInfo
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- CN111767666B CN111767666B CN202010589293.7A CN202010589293A CN111767666B CN 111767666 B CN111767666 B CN 111767666B CN 202010589293 A CN202010589293 A CN 202010589293A CN 111767666 B CN111767666 B CN 111767666B
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- G06F30/20—Design optimisation, verification or simulation
- G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
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Abstract
The invention relates to a CAE simulation method for laser welding connection of automobile parts, belonging to the technical field of finite element analysis and comprising the following steps of: step one, a sample wafer level joint mechanical property test is carried out, and mechanical characteristic parameters of a laser welding head are obtained through sample wafer tests under two working conditions of lap joint and angle joint; step two, establishing and calibrating a detailed model of the laser welding head, establishing a detailed model of an entity unit by applying LS-DYNA software, and adjusting model parameters; and step three, establishing and calibrating a laser welding head simplified model, and extracting parameters of the entity unit detailed model by using LS-DYNA software so as to establish a shell unit simplified model and adjust the parameters of the model. The simulation method can improve the calculation stability and accuracy of CAE simulation of the laser welding head of the steel-aluminum hybrid vehicle body and accurately simulate the non-uniformity of the mechanical property of the laser welding head.
Description
Technical Field
The invention belongs to the technical field of finite element analysis, and particularly relates to a CAE simulation method for laser welding connection of automobile parts.
Background
The laser welding technology is a high-speed, non-contact and extremely small-deformation welding mode, and is very suitable for large-scale and continuous online processing. The automobile manufacturing field is the industry using the laser welding technology in the largest scale in the current industrial production, and at present, in the automobile field all over the world, the laser welding is widely applied to the welding of parts such as chassis, roofs, side walls, vehicle doors, vehicle body assemblies and the like and large-scale covering parts of vehicle bodies, and becomes a main technological means during vehicle body assembly. With the wide application of laser welding technology in automobile body manufacturing, laser welding gradually replaces the traditional welding process and becomes one of the main welding means in the automobile manufacturing process. With the increasing of the automobile demand, the improvement of safety performance and the development trend of light weight, the original spot welding technology is difficult to meet the requirements. The laser welding has the advantages of small unit heat input quantity, small thermal deformation, large depth-to-width ratio of welding lines, high welding speed, higher strength coefficient after welding, unilateral processing of the laser welding, good adaptability of complex structures, capability of welding multilayer plates, easiness in realizing remote welding and automation and the like, so the laser welding gradually becomes a standard processing technology in the automobile industry of developed countries.
The existing laser welding head simulation methods mainly include a common node method, a rigid unit connection method, a beam unit connection method, a solid unit modeling method and the like. The common node method and the rigid unit connection method have the characteristic of no failure, and the beam unit connection method and the solid unit modeling method can simulate the failure of the connection point but cannot accurately simulate the non-uniformity of the mechanical property of the laser welding head. With the popularization of laser welding technology, it is important to develop a high-accuracy joint simulation method.
Disclosure of Invention
The invention provides a CAE simulation method for laser welding connection of automobile parts, aiming at solving the problem of low CAE simulation precision of the existing laser welding head of a steel-aluminum mixed automobile body, and improving the calculation stability and accuracy of CAE simulation of the laser welding head of the steel-aluminum mixed automobile body.
In order to solve the technical problems, the invention is realized by the following technical scheme:
a CAE simulation method for laser welding connection of automobile parts comprises the following steps:
the method comprises the following steps: the mechanical property test of the sample level joint is carried out, and the mechanical property parameters of the laser welding head are obtained through the sample test under two working conditions of lap joint and angle joint;
step two: establishing and calibrating a detailed model of a laser welding head, establishing a detailed model of an entity unit by applying LS-DYNA software, and adjusting model parameters;
step three: and establishing and calibrating a laser welding head simplified model, and extracting parameters of the entity unit detailed model by using LS-DYNA software so as to establish a shell unit simplified model and adjust model parameters.
After the third step, the method further comprises the following steps:
step four: and (3) performing component-level impact test and simulation calibration, developing the component-level impact test with the laser welding head, establishing a component impact test simulation model according to the laser welding head simplified model calibrated in the third step, adjusting model parameters, and confirming the final laser welding head simulation model by combining simulation and test joint failure modes.
When the detailed model is calibrated, the model parameters are adjusted until the fitting degree of simulation and a test force-displacement curve COR reaches more than 90 percent.
When the model calibration is simplified, model parameters are adjusted until the fitting degree of simulation and a test force-displacement curve COR reaches more than 85%.
When the simulation model of the part impact test is calibrated, the model parameters are adjusted until the fitting degree of the simulation and the test force-displacement curve COR reaches more than 85 percent.
The model parameters are material failure curve coefficient, weld zone width and fusion line width.
And the detailed model in the second step comprises four parts, namely an upper plate base metal, a lower plate base metal, a welding seam area and a fusion line, wherein the penetration depth of the upper and lower plate materials is obtained by a sample wafer joint molten pool shape graph, the penetration depth of the upper and lower plate materials is the width of the fusion line added to the welding seam area, and the welding seam area and the fusion line are obtained by a sample wafer hardness distribution curve.
And the simplified model in the third step comprises four parts, namely an upper plate base material, a lower plate base material, a welding seam area and a fusion line, wherein the four parts are respectively modeled by utilizing a shell unit.
The mesh size was 1mm using a simplified model built from shell elements.
The unit size of the solid unit detailed model is 1mm.
The invention has the beneficial effects that:
1. the simulation method of the invention respectively provides a detailed solid unit model, a simplified shell unit model and a simulation model for a component impact test, which can be respectively used as detailed failure models of the laser welding head, and can accurately simulate the mechanical property nonuniformity of the laser welding head by combining the material failure settings of the base metal and the affected area.
2. The model parameters used by the invention are obtained from sample blocks, component tests and simulation calibration, so that the method is easy to implement, and the simulation of the laser welding head with different process parameters can be quickly realized by adjusting a small amount of model parameters.
3. The invention can accurately simulate the failure process of the laser welding head of the steel-aluminum hybrid vehicle body in the collision of the whole vehicle, and is used for guiding the development of the safety performance of the connection of the steel-aluminum hybrid vehicle body.
Drawings
FIG. 1 is an overall architecture of the present invention;
FIG. 2 is a simplified model of a lap joint of the present invention;
FIG. 3 is a simplified model of the corner joint of the present invention;
FIG. 4 illustrates a laser welding head model calibration process of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the following drawings and specific embodiments. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It should be noted that the terms "front", "back", "left", "right", "upper" and "lower" used in the following description refer to directions in the drawings, and the terms "inner" and "outer" refer to directions toward and away from the geometric center of a specific part, respectively, and those skilled in the art should not understand that the techniques beyond the scope of the present application are simple and need no inventive adjustment.
In the description of the present invention, unless otherwise specified or limited, the term "connected" is to be understood broadly, and may be, for example, a mechanical connection or an electrical connection, or a communication between two elements, or may be a direct connection or an indirect connection through an intermediate medium, and the specific meaning of the above terms may be understood by those skilled in the art according to specific situations.
As shown in fig. 1 to 4, the CAE simulation method for laser welding connection of automobile parts according to the present invention includes the following steps:
step one, carrying out a sample wafer level joint mechanical property test, and obtaining a load-displacement mechanical property parameter of a laser welding head through sample wafer tests under two working conditions of lap joint and angle joint.
And step two, establishing a detailed model of the connector sample test by applying LS-DYNA software, wherein the model is established by adopting a solid unit, and the unit size is 1mm. The detailed model comprises an upper plate base metal, a lower plate base metal, a welding seam area and a fusion line, wherein the fusion depths (the widths of the welding seam area and the fusion line) of the upper plate base metal and the lower plate base metal are obtained from a sample wafer joint molten pool appearance graph, and the boundary line between the welding seam area and the fusion line is obtained from a sample wafer hardness distribution curve. And adjusting the coefficient of the material failure curve and the widths of a welding line area and a fusion line until the fitting degree of simulation and a test force-displacement curve COR reaches more than 90 percent.
And step three, applying LS-DYNA software to establish a simplified model of a connector sample test, wherein the model comprises four parts, namely an upper plate base material, a lower plate base material, a welding seam area and a fusion line. The model is modeled by adopting a shell unit, and the size of a grid is 1mm. The coefficient of the material failure curve, the width of the welding seam area and the width of the fusion line are obtained by a fine model. And adjusting the coefficient of the material failure curve, the width of a welding seam area and a fusion line to ensure that the fitting degree of the force-displacement curve of the simplified model and the COR (continuous operational reference) of a test curve is more than 85 percent.
And fourthly, carrying out the impact test and the simulation calibration of the component level with the laser welding head, and establishing a simulation model of the component impact test according to the joint simplified model calibrated in the third step. The fitting degree of a simulated and tested force-displacement curve COR reaches more than 85 percent by adjusting the coefficient of a material failure curve, the width of a welding seam area and the width of a fusion line. And (4) combining the simulation and the failure mode of the test joint to determine a final laser welding head simulation model.
The method uses parameters obtained from sample wafer, component level impact test and simulation calibration, and combines with material failure setting of the base metal and the affected area, so as to improve the accuracy of simulating the failure process of the laser welding head of the steel-aluminum hybrid vehicle body in the whole vehicle collision.
The laser welding head model calibration process is as follows: and (3) performing a sample wafer level joint mechanical property test and a component level impact test, then establishing a joint detailed model, comparing the joint detailed model with the sample wafer level joint mechanical property test, and judging whether the joint detailed model is consistent with the sample wafer level joint mechanical property test. If the connection is not matched, modifying and establishing a joint detailed model; and if the two materials are matched, outputting material parameter information.
And establishing a joint simplified model by utilizing the output material parameter information, comparing the joint simplified model with a sample-level joint mechanical property test, and judging whether the joint simplified model is consistent with the sample-level joint mechanical property test. If not, modifying and establishing a joint simplified model; and if the two are matched, preliminarily determining a joint simulation model.
And establishing a part impact test simulation model according to the preliminarily determined joint simulation model. And comparing the part impact model with the part-level impact test to judge whether the part impact model is consistent with the part-level impact test. If the parts do not conform to each other, modifying the part impact model; and if the two are matched, finally establishing a joint simulation model.
It should be understood that although the present invention has been described in terms of embodiments, not every embodiment includes only a single embodiment, and such description is for clarity only, and those skilled in the art will recognize that the embodiments described herein may be combined as a whole to form other embodiments as would be understood by those skilled in the art.
It should be noted that the above embodiments are only for explaining the technical solutions of the present invention, and are not intended to limit the scope of the present invention, and equivalent embodiments or modifications made without departing from the technical spirit of the present invention should be included in the scope of the present invention.
Claims (7)
1. A CAE simulation method for laser welding connection of automobile parts is characterized by comprising the following steps:
the method comprises the following steps: the mechanical property test of the sample level joint, namely obtaining the mechanical property parameters of the laser welding head through the sample test under two working conditions of lap joint and angle joint;
step two: establishing and calibrating a detailed model of a laser welding head, establishing a detailed model of an entity unit by applying LS-DYNA software, and adjusting model parameters, wherein the detailed model comprises four parts, namely an upper plate base metal, a lower plate base metal, a welding seam area and a fusion line, wherein the fusion depths of the upper and lower plate materials are obtained by a sample wafer joint molten pool appearance diagram, the fusion depths of the upper and lower plate materials are the widths of the fusion line added to the welding seam area, the boundary line between the welding seam area and the fusion line is obtained by a sample wafer hardness distribution curve, and the model parameters are a material failure curve coefficient, the width of the welding seam area and the width of the fusion line;
step three: establishing and calibrating a laser welding head simplified model, and extracting parameters of a detailed entity unit model by using LS-DYNA software so as to establish a shell unit simplified model and adjust the model parameters, wherein the simplified model comprises four parts, namely an upper plate base material, a lower plate base material, a welding seam area and a fusion line, and the four parts are respectively modeled by using shell units.
2. The CAE simulation method for laser welding connection of automobile parts according to claim 1, wherein after the third step, the method further comprises:
step four: and (3) carrying out component-level impact test and simulation calibration, developing the component-level impact test with the laser welding head, establishing a component impact test simulation model according to the laser welding head simplified model calibrated in the third step, adjusting model parameters, and confirming the final laser welding head simulation model by combining simulation and test joint failure modes.
3. The CAE simulation method for laser welding connection of automobile parts according to claim 1, wherein during detailed model calibration, model parameters are adjusted until the fitting degree of simulation and a test force-displacement curve COR reaches more than 90%.
4. The CAE simulation method for laser welding connection of automobile parts according to claim 1, wherein model parameters are adjusted until the fitting degree of simulation and a test force-displacement curve COR reaches more than 85% when model calibration is simplified.
5. The CAE simulation method for laser welding connection of automobile parts as claimed in claim 2, wherein when the part impact test simulation model is calibrated, model parameters are adjusted until the fitting degree of simulation and a test force-displacement curve COR reaches more than 85%.
6. The CAE simulation method for laser welding connection of automobile parts according to claim 1, wherein a simplified model built by the shell unit is used, and the size of the grid is 1mm.
7. The CAE simulation method of laser welding connection of automobile parts according to claim 1, wherein the physical unit detail model has a unit size of 1mm.
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| CN112464401B (en) * | 2020-11-24 | 2022-07-22 | 一汽奔腾轿车有限公司 | Accurate modeling method for metal material welding spot |
| CN112818465B (en) * | 2021-01-28 | 2022-12-27 | 上海中氐实业股份有限公司 | Method and system for predicting failure of welding spot |
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