CN111950183A - Heat source loading method and system suitable for complex large component - Google Patents
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Abstract
The invention discloses a heat source loading method suitable for a complex large component, which comprises the steps of constructing a thermo-elastic-plastic finite element model of a typical joint, and determining a thermal cycle curve of the center position of a welding seam; scaling the thermal cycle curve in time according to the actual welding process to obtain the thermal cycle curve as a welding heat source; and (3) equating a plurality of welding seams in the thermal elastic-plastic finite element model to be one welding seam, and loading a thermal cycle curve used as a welding heat source. A corresponding system is also disclosed. The invention calculates the thermal cycle curve as the welding heat source based on the thermal cycle curve obtained by simulating the typical joint, then a plurality of (n) welding seams in the model are equivalent to one welding seam, the thermal cycle curve as the welding heat source is loaded, the required time is 1/n of the original time, and for huge complex components, the calculation time can be greatly reduced in the simulation process, and the efficiency is improved.
Description
Technical Field
The invention relates to a heat source loading method and system suitable for a complex large component, and belongs to the field of finite element simulation heat source loading.
Background
In recent years, the development of rail transit industry has promoted the progress and perfection of rail vehicle processing technology. The structural members (such as the front end, the underframe and the side wall) of the railway vehicle body have the characteristics of complex shape, large structural size, strict surface quality requirement and the like, and most of the structural members are formed by welding thick aluminum alloy plates. The welding procedures of the complex structural parts are complex and various, the distribution of welding seams is irregular, and the characteristics of the aluminum alloy material are different, so that the welding process is easy to generate larger welding stress and deformation, especially the multilayer and multi-pass welding of the aluminum alloy thick plate. The correction of welding defects is time-consuming and labor-consuming, the cost is extremely high, the effect is not obvious, and the influence on the structural strength of the vehicle body, the operation safety of the vehicle and the production cycle of the product is large. With the development of computer technology and welding numerical simulation, a finite element method is adopted to carry out welding process simulation on the track type complex component, so that the optimization of welding procedures and technological parameters is realized, the cost can be greatly reduced, and the efficiency is improved. Therefore, the optimization of the welding process design by adopting a finite element numerical simulation method is an important method for solving the welding problem.
The welding process finite element numerical simulation method generally comprises the processes of geometric modeling, mesh division, material parameter loading, welding path definition, boundary condition and heat source model definition, calculation solution and the like. The heat source model is the basis of numerical simulation, the simulation accuracy of the welding temperature field and the stress field can be improved by establishing the accurate heat source model, and the excessively complicated heat source model can cause the situations of overlarge calculated amount, increased error and the like. When the traditional heat source loading method is directly utilized to carry out numerical simulation on a complex large component, the calculation amount is huge, certain requirements are placed on the grid division mode of the model, and the time required by the whole simulation process can be half a year or even one year.
Disclosure of Invention
The invention provides a heat source loading method and system suitable for complex large components, and solves the problems disclosed in the background technology.
In order to solve the technical problems, the technical scheme adopted by the invention is as follows:
a heat source loading method suitable for complex large components comprises the following steps,
constructing a thermal elastic plastic finite element model of a typical joint, and determining a thermal cycle curve of the center position of a welding seam;
scaling the thermal cycle curve in time according to the actual welding process to obtain the thermal cycle curve as a welding heat source;
and (3) equating a plurality of welding seams in the thermal elastic-plastic finite element model to be one welding seam, and loading a thermal cycle curve used as a welding heat source.
And constructing a thermal elastic plastic finite element model of a typical joint, loading a double-ellipsoid heat source, and determining a thermal cycle curve of the center position of the welding seam.
Constructing a thermo-elastic-plastic finite element model of a typical joint, loading a double-ellipsoid heat source, and determining a thermal cycle curve of the center position of a welding seam,
constructing a thermo-elastic-plastic finite element model of a typical joint, and loading a double-ellipsoid heat source;
comparing the simulated molten pool section with the actual weld morphology, checking a heat source, and obtaining double-ellipsoid heat source parameters;
and solving a partial differential equation of heat conduction of the welding seam based on a double-ellipsoid heat source to obtain a heat cycle curve of the central position of the welding seam.
The thermal cycle curve equation of the seam center position is,
q is double-ellipsoid heat source intensity, T is temperature, c is specific heat capacity of welding parent metal, rho is density of welding parent metal, x, y and z are any point in a rectangular coordinate system in a solution domain, kx, ky and kzIs the heat conduction coefficient of the welded metal material in the x, y, z directions.
And zooming the thermal cycle curve in time according to the actual welding process to enable the time on the thermal cycle curve to correspond to the corresponding time in the actual welding process, so as to obtain the thermal cycle curve serving as a welding heat source.
The method further comprises the step of carrying out validity verification on the thermal cycle curve based on a thermal elastic plastic finite element model loaded with the thermal cycle curve, and responding to verification that the loaded thermal cycle curve is proper.
The process of the validity verification is that,
acquiring stress values of a plurality of welding seam measuring points based on a thermal elastic plastic finite element model loaded with a thermal cycle curve;
and comparing the stress value of the welding line measuring point with the corresponding measured data, responding to the comparison result meeting the preset requirement, and passing the validity verification.
A heat source loading system suitable for complex large components comprises,
thermal cycle profile module: constructing a thermal elastic plastic finite element model of a typical joint, and determining a thermal cycle curve of the center position of a welding seam;
a scaling module: scaling the thermal cycle curve in time according to the actual welding process to obtain the thermal cycle curve as a welding heat source;
loading a module: and (3) equating a plurality of welding seams in the thermal elastic-plastic finite element model to be one welding seam, and loading a thermal cycle curve used as a welding heat source.
A computer readable storage medium storing one or more programs, the one or more programs comprising instructions, which when executed by a computing device, cause the computing device to perform a heat source loading method suitable for complex large components.
A computing device comprising one or more processors, memory, and one or more programs stored in the memory and configured to be executed by the one or more processors, the one or more programs comprising instructions for performing a heat source loading method suitable for complex large components.
The invention achieves the following beneficial effects: the invention calculates the thermal cycle curve as the welding heat source based on the thermal cycle curve obtained by simulating the typical joint, then a plurality of (n) welding seams in the model are equivalent to one welding seam, the thermal cycle curve as the welding heat source is loaded, the required time is 1/n of the original time, and for huge complex components, the calculation time can be greatly reduced in the simulation process, and the efficiency is improved.
Drawings
FIG. 1 is a flow chart of the method of the present invention;
FIG. 2 is a finite element model of a typical joint;
FIG. 3 is a thermal cycle plot of a center position of a typical joint weld;
FIG. 4 is a graph of thermal cycling as a welding heat source;
FIG. 5 is a schematic view of a stress measurement site;
FIG. 6 is a graph comparing experimental measurements to simulated values.
Detailed Description
The invention is further described below with reference to the accompanying drawings. The following examples are only for illustrating the technical solutions of the present invention more clearly, and the protection scope of the present invention is not limited thereby.
As shown in fig. 1, a heat source loading method suitable for a complex large component includes the following steps:
The specific process is as follows:
11) constructing a thermo-elastic-plastic finite element model of a typical joint, and loading a double-ellipsoid heat source; the method specifically comprises the following steps:
s1) establishing a three-dimensional geometric model of a typical joint on a certain railway vehicle member;
s2) carrying out meshing on the three-dimensional geometric model according to the welding condition, wherein the meshed model is shown in figure 2; the method comprises the steps of dividing a welding line and a region within a preset distance (generally 20mm) from the welding line into dense grids, dividing a region outside the preset distance (generally 20mm) into sparse grids, adopting transition grids between the dense grids and the sparse grids, wherein the number of units in a model is 60950, and the number of nodes is 74227. The multilayer multi-pass welding needs to establish welding seam units respectively, as shown in figure 2I;
s3) loading material thermophysical property parameters including specific heat capacity, thermal conductivity, Young modulus, thermal expansion coefficient, yield strength and the like;
s4) loading initial conditions of the finite element model, defining thermal boundary conditions and heat exchange boundary conditions, wherein the thermal boundary conditions comprise an environment initial temperature, a heat exchange unit, clamping conditions, spot welding constraints and the like;
s5) loading a double-ellipsoid heat source model, namely loading heat in the double-ellipsoid heat source model onto a weld joint of the finite element model;
the double-ellipsoid heat source model is as follows,
wherein q isf(x,y,z)、qr(x, y, z) are respectively the heat input of the front half ellipsoid and the rear half ellipsoid, x, y and z are any point in a rectangular coordinate system in a solution domain, a and b respectively represent the length and the depth of a corresponding hemisphere, ff、frThe heat distribution coefficients of the front half ellipsoid and the rear half ellipsoid, respectively, ff+frQ is double ellipsoid heat source intensity, cf、crThe widths of the front half ellipsoid and the rear half ellipsoid respectively;
s6) comparing the simulated weld pool section with the actual weld seam appearance, checking the heat source, and obtaining double-ellipsoid heat source parameters;
13) solving a partial differential equation of heat conduction of the welding seam based on a double-ellipsoid heat source to obtain a heat cycle curve of the central position of the welding seam, which is shown in figure 3;
the thermal cycle curve equation of the seam center position is,
wherein Q is the strength of a double-ellipsoid heat source, T is the temperature, c is the specific heat capacity of the welding parent metal, rho is the density of the welding parent metal, and kx、ky、kzIs the heat conduction coefficient of the welded metal material in the x, y, z directions.
And 2, zooming the thermal cycle curve in time according to the actual welding process, so that the time on the thermal cycle curve corresponds to the corresponding time in the actual welding process, and obtaining the thermal cycle curve serving as a welding heat source.
Assuming that the welding start time of the Nth welding seam is t1The welding end time is t2If the duration of the heating and cooling whole phase in the thermal cycle curve t (t) calculated for the typical joint corresponding to the weld is Δ t, the expression of the scaled nth thermal cycle curve is:
wherein t' is a certain time of the Nth welding seam welding process, t1≤t′≤t2The thermal cycling profile required during the actual simulation is shown in fig. 4, with the entire welding process lasting 46 seconds.
And 3, equating a plurality of welding seams in the thermal elastic plastic finite element model to be one welding seam, and loading a thermal cycle curve used as a welding heat source.
Step 4, based on the thermal elastic plastic finite element model loaded with the thermal cycle curve, carrying out validity verification on the thermal cycle curve, and responding to the verification that the loaded thermal cycle curve is proper; and if the verification fails, modifying the double-ellipsoid heat source model, and calculating the thermal cycle curve again until the verification passes.
The process of validity verification is as follows:
A1) acquiring stress values of a plurality of welding seam measuring points based on a thermal elastic plastic finite element model loaded with a thermal cycle curve;
obtaining the temperature field distribution of the joint in the welding process by solving a heat conduction partial differential equation; and solving the thermal elastic plastic stress finite element model to obtain the dynamic stress strain process of the joint in the whole welding process and the final residual stress and deformation state.
A2) And comparing the stress value of the welding line measuring point with the corresponding measured data, responding to the comparison result meeting the preset requirement, and passing the validity verification.
The blind hole method is adopted to measure the stress of the welding seam after spot welding, 4 points which are vertical to the welding seam are taken as the welding seam measuring points, the distances from the welding seam measuring points to the edge are respectively 35mm, 55mm, 75mm and 95mm, and the schematic diagram is shown in figure 5. And extracting stress field simulation results of corresponding positions, and comparing the stress field simulation results with experimental measurement results, as shown in fig. 6.
In order to further explain the method, the numerical simulation of the multi-layer and multi-pass welding process of the aluminum alloy thick plate is analyzed in detail, and the specific steps are as follows:
the 6005A-T6 and 6082-T6 aluminum alloy slabs with dimensions of 300mm by 150mm by 12mm were used. The L-shaped joint adopts MIG multilayer multi-pass welding process, 4 welding seams are totally formed, and the main welding process parameters are shown in table 1:
TABLE 1 MIG welding process parameters table
The thermo-physical performance parameters used for the finite element simulation of the welding process are shown in tables 2 and 3:
TABLE 26082 thermophysical parameters of aluminum alloys
TABLE 36005A thermal Property parameters of the aluminum alloys
Step a, establishing a multilayer multi-pass welding thermoplastic finite element model aiming at a typical joint on a certain railway vehicle structure, and acquiring a thermal cycle curve of the center position of a welding seam, as shown in figure 3;
step b: scaling the thermal cycle curve obtained in the step a in time according to the actual welding process to obtain a thermal cycle curve used as a welding heat source, as shown in fig. 4;
step c: and (c) equating a plurality of welding seams of the welding joint finite element model established in the step (a) to be one welding seam, and loading the thermal cycle curve obtained by calculation in the step (b) to all welding seam nodes so as to solve the temperature field, the stress field and the welding deformation.
Step d: the blind hole method is adopted in the experiment to measure the post-welding stress of the joint, 4 measuring points (namely welding seam measuring points) perpendicular to the welding seam are taken, the distances from the edges of the measuring points to the edges are respectively 35mm, 55mm, 75mm and 95mm, and meanwhile, the simulation result is taken to be compared with the experimental value, as shown in figure 6, the simulation values of the measuring points No. 1, 3 and 4 can be seen in the figure to be well matched with the experimental value, wherein the error of the measuring point No. 2 is larger, but the error existing in the experimental measurement and model simplification is considered, and the result is within the acceptance range. The solving time of the heat source loading method is one fourth of that of the original method, so that the heat source loading method is feasible for finite element simulation of complex components.
The invention calculates the thermal cycle curve as the welding heat source based on the thermal cycle curve obtained by simulating the typical joint, then a plurality of (n) welding seams in the model are equivalent to one welding seam, the thermal cycle curve as the welding heat source is loaded, the required time is 1/n of the original time, and for huge complex components, the calculation time can be greatly reduced in the simulation process, and the efficiency is improved.
A heat source loading system suitable for complex large components comprises,
thermal cycle profile module: constructing a thermal elastic plastic finite element model of a typical joint, and determining a thermal cycle curve of the center position of a welding seam;
a scaling module: scaling the thermal cycle curve in time according to the actual welding process to obtain the thermal cycle curve as a welding heat source;
loading a module: and (3) equating a plurality of welding seams in the thermal elastic-plastic finite element model to be one welding seam, and loading a thermal cycle curve used as a welding heat source.
A computer readable storage medium storing one or more programs, the one or more programs comprising instructions, which when executed by a computing device, cause the computing device to perform a heat source loading method suitable for complex large components.
A computing device comprising one or more processors, memory, and one or more programs stored in the memory and configured to be executed by the one or more processors, the one or more programs comprising instructions for performing a heat source loading method suitable for complex large components.
As will be appreciated by one skilled in the art, embodiments of the present application may be provided as a method, system, or computer program product. Accordingly, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present application may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, and the like) having computer-usable program code embodied therein.
The present application is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the application. It will be understood that each flow and/or block of the flow diagrams and/or block diagrams, and combinations of flows and/or blocks in the flow diagrams and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
The present invention is not limited to the above embodiments, and any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention are included in the scope of the claims of the present invention which are filed as the application.
Claims (10)
1. A heat source loading method suitable for a complex large component is characterized by comprising the following steps: comprises the steps of (a) preparing a mixture of a plurality of raw materials,
constructing a thermal elastic plastic finite element model of a typical joint, and determining a thermal cycle curve of the center position of a welding seam;
scaling the thermal cycle curve in time according to the actual welding process to obtain the thermal cycle curve as a welding heat source;
and (3) equating a plurality of welding seams in the thermal elastic-plastic finite element model to be one welding seam, and loading a thermal cycle curve used as a welding heat source.
2. A heat source loading method suitable for a complex large component according to claim 1, wherein: and constructing a thermal elastic plastic finite element model of a typical joint, loading a double-ellipsoid heat source, and determining a thermal cycle curve of the center position of the welding seam.
3. A heat source loading method suitable for a complex large component according to claim 2, wherein: constructing a thermo-elastic-plastic finite element model of a typical joint, loading a double-ellipsoid heat source, and determining a thermal cycle curve of the center position of a welding seam,
constructing a thermo-elastic-plastic finite element model of a typical joint, and loading a double-ellipsoid heat source;
comparing the simulated molten pool section with the actual weld morphology, checking a heat source, and obtaining double-ellipsoid heat source parameters;
and solving a partial differential equation of heat conduction of the welding seam based on a double-ellipsoid heat source to obtain a heat cycle curve of the central position of the welding seam.
4. A heat source loading method suitable for a complex large component according to claim 3, wherein: the thermal cycle curve equation of the seam center position is,
q is double-ellipsoid heat source intensity, T is temperature, c is specific heat capacity of welding parent metal, rho is density of welding parent metal, x, y and z are any point in a rectangular coordinate system in a solution domain, and k isx、ky、kzIs the heat conduction coefficient of the welded metal material in the x, y, z directions.
5. A heat source loading method suitable for a complex large component according to claim 1, wherein: and zooming the thermal cycle curve in time according to the actual welding process to enable the time on the thermal cycle curve to correspond to the corresponding time in the actual welding process, so as to obtain the thermal cycle curve serving as a welding heat source.
6. A heat source loading method suitable for a complex large component according to claim 1, wherein: the method further comprises the step of carrying out validity verification on the thermal cycle curve based on a thermal elastic plastic finite element model loaded with the thermal cycle curve, and responding to verification that the loaded thermal cycle curve is proper.
7. A heat source loading method suitable for a complex large component according to claim 6, wherein: the process of the validity verification is that,
acquiring stress values of a plurality of welding seam measuring points based on a thermal elastic plastic finite element model loaded with a thermal cycle curve;
and comparing the stress value of the welding line measuring point with the corresponding measured data, responding to the comparison result meeting the preset requirement, and passing the validity verification.
8. A heat source loading system suitable for complex large components, characterized by: comprises the steps of (a) preparing a mixture of a plurality of raw materials,
thermal cycle profile module: constructing a thermal elastic plastic finite element model of a typical joint, and determining a thermal cycle curve of the center position of a welding seam;
a scaling module: scaling the thermal cycle curve in time according to the actual welding process to obtain the thermal cycle curve as a welding heat source;
loading a module: and (3) equating a plurality of welding seams in the thermal elastic-plastic finite element model to be one welding seam, and loading a thermal cycle curve used as a welding heat source.
9. A computer readable storage medium storing one or more programs, characterized in that: the one or more programs include instructions that, when executed by a computing device, cause the computing device to perform any of the methods of claims 1-7.
10. A computing device, characterized by: comprises the steps of (a) preparing a mixture of a plurality of raw materials,
one or more processors, memory, and one or more programs stored in the memory and configured to be executed by the one or more processors, the one or more programs including instructions for performing any of the methods of claims 1-7.
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