CN112380752B - Method for improving welding process of metal sheet by predicting welding heat treatment value of metal sheet - Google Patents

Method for improving welding process of metal sheet by predicting welding heat treatment value of metal sheet Download PDF

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CN112380752B
CN112380752B CN202011323699.7A CN202011323699A CN112380752B CN 112380752 B CN112380752 B CN 112380752B CN 202011323699 A CN202011323699 A CN 202011323699A CN 112380752 B CN112380752 B CN 112380752B
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葛建立
肖越
杨国来
孙全兆
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Nanjing University of Science and Technology
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Abstract

The invention discloses a method for improving a welding process by predicting a welding heat treatment value of a metal sheet, which comprises the steps of firstly establishing a metal sheet welding thermal coupling finite element analysis model, and setting initial conditions and boundary conditions of the thermal coupling finite element analysis model in the metal sheet welding process; then establishing a welding heat source equation of the metal sheet; carrying out numerical simulation in the welding process to obtain the distribution of a temperature field and a stress field of the welded metal sheet and the distribution of residual stress of the welded metal sheet; and finally, taking the residual stress obtained by calculation in the welding process as an initial condition, taking the residual stress as post-welding heat treatment simulation calculation, and analyzing the elimination condition of the post-heat treatment welding residual stress. The invention can carry out numerical simulation analysis on the welding and heat treatment processes of the metal sheet to obtain the temperature field in the welding process and the distribution conditions of the residual stress after welding and heat treatment, and provides a technical basis for predicting the residual stress in the welding process and the heat treatment process of the metal sheet in engineering.

Description

Method for improving welding process of metal sheet by predicting welding heat treatment value of metal sheet
Technical Field
The invention belongs to the technical field of welding numerical simulation, and particularly relates to a method for improving a welding process of a metal sheet by predicting a welding heat treatment numerical value of the metal sheet.
Background
In the welding process, because of the characteristic of high-density energy rapid heating, the titanium alloy inevitably generates residual stress and deformation after being subjected to welding temperature circulation. The presence of residual stresses can promote brittle fracture, stress corrosion cracking, and reduce the fatigue strength of the component during service. The existence of welding residual stress can seriously affect the service performance of the welded structural part, so the control of the welding residual stress is a problem which must be considered in the process design and manufacturing process. With the development of computer numerical simulation technology, a physical model is established for a welding process, and numerical simulation analysis is performed.
Ge Keke in the thesis of residual stress simulation research of narrow gap welding of thick titanium alloy plates, finite element software is adopted to carry out numerical simulation on a temperature field and a stress field of a narrow gap welding joint of a thick titanium alloy plate, and the residual stress distribution rule of the thick titanium alloy plate is analyzed; zhang Jiacheng establishes a mathematical model of a welding three-dimensional stress field by applying a finite element method in a thesis of numerical simulation of TC4 titanium alloy laser welding, and performs numerical simulation by using ABAQUS finite element software by taking a TC4 thin plate as an example to obtain a distribution rule of a transient temperature field and a residual stress field of the TC4 thin plate; in the above, the distribution of residual stress after the post-weld heat treatment is not considered, so that the welding process and the post-weld heat treatment numerical simulation of the metal sheet can be performed to guide the actual welding process and the process parameters of the heat treatment.
Disclosure of Invention
The invention aims to provide a method for improving a welding process by predicting a welding heat treatment value of a metal sheet, which solves the problem that residual stress after welding and postweld heat treatment of the metal sheet influences the selection of welding and heat treatment process parameters.
The technical solution for realizing the purpose of the invention is as follows: a method for improving a welding process of a metal sheet by utilizing a predicted welding heat treatment value of the metal sheet comprises the following steps:
firstly, establishing a thermodynamic coupling model calculation model in the metal sheet welding process:
establishing a metal sheet butt-joint laser welding model by using finite element software, wherein an eight-node hexahedron unit is adopted as a grid unit, and the grid close to the welding seam is subdivided; setting thermophysical property parameters of the metal along with temperature change; namely the modulus of elasticity, the plastic curve, the thermal conductivity and the thermal expansion coefficient of the metal at different temperatures.
Step two, setting initial conditions and boundary conditions of a metal sheet welding model:
temperature boundary conditions: the welding environment temperature is set to room temperature in the initial condition. And setting boundary heat exchange condition parameters, namely heat exchange coefficients and heat radiation condition parameters. All the outer wall surfaces of the metal sheets are heat exchange surfaces;
structural boundary conditions: the sheet can be freely deformed without rigid body movement under the typical three-point constraint free deformation constraint condition that three continuous vertexes on the upper surface of the sheet are taken to respectively constrain the translational degrees of freedom in three directions of XYZ, YZ and Z; and loading the user-defined mobile body heat source load.
Thirdly, establishing a welding heat source equation of the metal sheet:
establishing a double-ellipsoid heat source model, wherein the front half part and the rear half part of the heat source model are respectively 1/4 of ellipsoids, and the heat sources of the ellipsoids of the front half part and the rear half part are distributed as follows:
Figure BDA0002793652540000021
Figure BDA0002793652540000022
wherein q is 1 、q 2 The heat generation rate of the front half part and the rear half part; a is a 1 、a 2 B and c are half-axis parameters of the double ellipsoids; i is welding current; u is welding voltage; eta is welding efficiency; f. of f And f r Is a function of the heat distribution of the front and rear ellipsoids, and f f +f r ＝2。
Fourthly, calling a welding heat source equation of the metal sheet by the finite element software, carrying out numerical simulation on the welding process by combining a thermodynamic coupling finite element analysis model of the welding process of the metal sheet, and carrying out heat transfer analysis on the finite element software based on a differential equation of heat transfer control:
Figure BDA0002793652540000023
wherein rho, c and lambda are the density, specific heat capacity and thermal conductivity of the material respectively;
Figure BDA0002793652540000024
the strength of the internal heat source. Obtaining the temperature field and stress field distribution of the metal sheet in the welding process after numerical simulation;
and fifthly, performing subsequent postweld heat treatment numerical simulation on the metal sheet by taking the residual stress obtained by calculation in the welding process as an initial condition.
And in the heat treatment and heat preservation stage, the softening effect and the creep effect of the material are considered, and the material is cooled to room temperature by adopting an air cooling method. The creep behavior of metallic materials complies with the Norton creep law:
Figure BDA0002793652540000025
in the formula (I), the compound is shown in the specification,
Figure BDA0002793652540000026
for creep strain rate, σ is creep stress, n is stress index, A is material constant, Q is nominal creep activation energy, and T is temperature. And obtaining the residual stress field distribution of the metal sheet after welding heat treatment after numerical simulation.
And a sixth step: and guiding to improve welding process parameters according to the distribution of the residual stress field of the post-welding heat treatment of the metal sheet.
Drawings
FIG. 1 is a flow chart of a method of the present invention for improving a welding process using a predicted heat treatment value for welding sheet metal.
FIG. 2 is a grid-divided view of a thin TC4 titanium alloy sheet according to the present invention.
FIG. 3 is a temperature profile of the TC4 titanium alloy sheet during the welding process for 13 s.
FIG. 4 is a cloud of stress distributions of the TC4 titanium alloy sheet during a welding process for 10 s.
FIG. 5 is a cloud of stress distributions at the end of the welding process for TC4 titanium alloy sheets according to the present invention.
FIG. 6 is a graph of stress at the center of a TC4 titanium alloy thin plate weld during welding according to the present invention over time.
FIG. 7 is a cloud of stress distributions at the end of the post-weld cooling process for a TC4 titanium alloy sheet of the present invention.
FIG. 8 is a cloud of stress distributions at the end of the post-weld heat treatment process for a TC4 titanium alloy sheet of the present invention.
FIG. 9 is a longitudinal residual stress distribution curve diagram of the TC4 titanium alloy thin plate after welding and heat treatment on the center line of the vertical weld joint.
Detailed Description
The invention is described in detail below with reference to the figures and the specific examples.
Referring to fig. 1, the method for improving the welding process by predicting the welding heat treatment value of the metal sheet according to the present invention includes the following steps:
firstly, establishing a thermodynamic coupling model calculation model in the metal sheet welding process:
and (3) establishing a metal sheet butt-joint laser welding model by using finite element software, selecting eight-node hexahedron units as grids, and subdividing the grids near the welding seam. And setting the thermophysical performance parameters of the metal along with the temperature change. I.e., the modulus of elasticity, plastic curve, thermal conductivity, coefficient of thermal expansion, etc., of the metal at different temperatures.
Step two, setting initial conditions and boundary conditions of a metal sheet welding model:
temperature boundary conditions: setting the welding environment temperature as room temperature. And setting boundary heat exchange condition parameters, namely heat exchange coefficients and heat radiation condition parameters. All the outer wall surfaces provided with the metal sheets are heat exchange surfaces.
Structural boundary conditions: according to a typical three-point constraint free deformation constraint condition, namely, three continuous vertexes on the upper surface of the thin plate are taken to respectively constrain the translational degrees of freedom in the three directions of XYZ, YZ and Z, the thin plate can be freely deformed without rigid body movement. And loading the user-defined mobile body heat source load.
Thirdly, establishing a welding heat source equation of the metal sheet:
establishing a double-ellipsoid heat source model, wherein the front half part and the rear half part of the heat source model are respectively 1/4 of ellipsoids, and the heat sources of the ellipsoids of the front half part and the rear half part are distributed as follows:
Figure BDA0002793652540000041
Figure BDA0002793652540000042
wherein q is 1 、q 2 The heat generation rate of the front half part and the rear half part; a is 1 、a 2 B and c are half-axis parameters of the double ellipsoids; i is welding current; u is welding voltage; eta is welding efficiency; f. of f As a function of the ellipsoidal heat distribution of the first half f r Is a function of the heat distribution of the ellipsoid of the second half part, and f f +f r =2; (x, y, z) are coordinates of the heat source center point in the global coordinate system of the finite element model.
Fourthly, calling a welding heat source equation of the metal sheet by the finite element software, carrying out numerical simulation on the welding process by combining a thermal coupling finite element analysis model in the welding process of the metal sheet, carrying out heat transfer analysis on the finite element software based on a differential equation of heat transfer control, wherein the thermal control differential equation is as follows:
Figure BDA0002793652540000043
wherein rho, c and lambda are respectively the density, specific heat capacity and thermal conductivity of the material;
Figure BDA0002793652540000044
the strength of the internal heat source. And obtaining the temperature field and stress field distribution of the metal sheet in the welding process after numerical simulation.
And fifthly, taking the residual stress obtained by calculation in the welding process as an initial condition, and carrying out subsequent post-welding heat treatment numerical simulation.
In the heat treatment and heat preservation stage, the softening effect and the creep effect of the material are considered, and the material is cooled to room temperature by adopting an air cooling method; the creep behaviour of the material follows the Norton creep law:
Figure BDA0002793652540000045
in the formula，
Figure BDA0002793652540000046
For creep strain rate, σ is creep stress, n is stress index, A is the material constant, Q is the nominal creep activation energy, and T is temperature. And obtaining the residual stress field distribution of the metal sheet after-welding heat treatment after numerical simulation.
And a sixth step: and guiding to improve welding process parameters according to the distribution of the residual stress field of the metal sheet after welding heat treatment.
Example 1
The following analysis is performed by taking the butt welding process and the post-weld heat treatment numerical simulation calculation of a TC4 titanium alloy sheet with the thickness of 3mm as an example, wherein the chemical components (wt.%) of the TC4 titanium alloy are as follows:
Al V Fe Si C N H O Ti
5.5-6.8 3.5-4.5 ≤0.30 ≤0.15 ≤0.10 ≤0.05 ≤0.015 ≤0.20 balance of
Step 1: establishing a thermal coupling calculation model of the TC4 titanium alloy sheet welding process:
1.1 according to the actual operating conditions, three-dimensional geometric model is established, for example, in figure 2, the size of TC4 titanium alloy sheet is 100mm x 3mm, and the welding seam with the length of 100mm and the fusion width of 8mm is arranged in the middle of the flat plate. And (3) exporting the model in an X _ T format, importing the model into Hypermesh finite element pretreatment software for grid division, selecting eight-node hexahedral units for grid division, and refining the grid from dense to sparse from the center of a welding seam to two sides. The number of nodes of the model is 22220 and the number of cells is 16200. Exporting the finite element model in an inp file format, and importing the file into ABAQUS finite element software for analysis;
1.2 setting the thermophysical performance parameters of the TC4 titanium alloy material along with the temperature change, including density, thermal conductivity coefficient, elastic modulus, poisson's ratio and thermal expansion coefficient. The thermo-physical performance parameters of the TC4 titanium alloy as a function of temperature are given in the following table:
Figure BDA0002793652540000051
step 2: setting initial conditions and boundary conditions of a weld model
Setting the welding initial temperature to be 20 ℃ in the initial step; establishing two thermal coupling analysis STEPs, wherein the first STEP is a welding analysis STEP STEP-1, the second STEP is a cooling analysis STEP STEP-2, the thermal coupling analysis STEP is provided with the condition parameters of air heat exchange, the thermal radiation and the thermal convection are comprehensively considered, and the heat exchange coefficient is 50W/m 2 K, the air temperature is 20 ℃; thermal radiationThe coefficient was 0.8. And adopting a constraint condition for preventing rigid body displacement on 3 nodes of the model. The option is to apply a time varying body heat flow over the welded component as a whole through a user-defined subroutine.
And step 3: establishing a welding heat source equation of the TC4 titanium alloy sheet
The DFLUX subprogram is edited by using Fortran language, a double-ellipsoid heat source model is established, and the heat source model is divided into the following two parts:
Figure BDA0002793652540000061
Figure BDA0002793652540000062
wherein q is 1 、q 2 The heat generation rate of the front half part and the rear half part; a is a 1 、a 2 B and c are half-axis parameters of the double ellipsoids; i is welding current; u is welding voltage; eta is welding efficiency; f. of f And f r Is a function of the heat distribution of the front and rear ellipsoids, and f f +f r =2, in the invention take f f ＝0.6，f r =1.4, u =9.5v, i =90a, η =0.8; the welding speed was 5mm/s.
And 4, step 4: the task is submitted to solve, and numerical simulation calculation is carried out in the welding process
And (3) creating an analysis task, selecting the user subprogram file established in the third step, calling the user subprogram by ABAQUS software, submitting the analysis, carrying out numerical simulation on the welding process, and carrying out heat transfer analysis by finite element software based on a differential equation of heat transfer control.
Figure BDA0002793652540000063
Wherein rho, c and lambda are respectively the density, specific heat capacity and thermal conductivity of the material;
Figure BDA0002793652540000064
the strength of the internal heat source.
Through a thermal coupling calculation model, based on material thermal parameters, a temperature field can be directly coupled to obtain the distribution conditions of a stress field and a temperature field. After the calculation is finished, the welding process temperature field can be obtained by entering post-processing, as shown in figure 3. When the welding time is 13s, the maximum temperature of the welded joint is 1950 ℃, the temperature along the weld penetration direction also exceeds the melting point (1668 ℃) of the titanium alloy, and the temperature peak appears in the central area of the weld.
The stress field during welding is shown in fig. 4 and 5. Along with the movement of the heat source, the part near the molten pool is heated and expanded, the surrounding temperature is lower, and the compression plastic deformation is generated around the molten pool under the constraint action to generate the compressive stress; as the heat source continues to advance, the temperature drops there causing shrinkage, the surrounding material limits its shrinkage, creating a tensile plastic deformation and finally a longitudinal residual tensile stress. FIG. 6 is a graph of stress at the center of a weld of a TC4 titanium alloy sheet over time during welding. The residual stress field after the cooling process is completed is shown in fig. 7.
And 5: postweld heat treatment numerical simulation
And (4) taking the residual stress obtained by calculation in the welding process as an initial condition, and performing postweld heat treatment simulation calculation. The finite element model is the same as the welding process. The process considers the creep effect of the material, the heat treatment test piece is long, the test piece has large residual stress after welding, and the creep effect in the heat treatment process can have obvious influence on the residual stress after welding. Heat treatment calculation procedure, assuming creep behavior of TC4 titanium alloys obeys the Norton creep criterion:
Figure BDA0002793652540000071
in the formula (I), the compound is shown in the specification,
Figure BDA0002793652540000072
for creep strain rate, σ is creep stress, n is stress index, A is material constant, Q is nominal creep activation energy, and T is temperature.
Wherein a =1.217, n =4.64, q =2.431e 4 . And compiling the expression by using a Fortran compiler according to the deep user subprogram grammar specification to establish a TC4 titanium alloy Creep subprogram file.
Setting a heat treatment analysis step, and respectively setting heating, heat preservation and cooling thermodynamic coupling analysis steps, wherein in the heating analysis, the temperature of the component is set to 600 ℃ in the boundary condition; in the thermal insulation analysis step, the boundary condition is set to be 600 ℃; in the cooling analysis step, the boundary condition setting member was cooled to room temperature of 20 ℃.
And establishing an analysis task, selecting an established titanium alloy creep subprogram file, calling the user subprogram by ABAQUS software, then submitting for analysis, carrying out numerical simulation on the post-welding heat treatment process, submitting for analysis and calculation, and obtaining a residual stress field of the TC4 titanium alloy sheet after-welding heat treatment.
Step 6: and guiding to improve welding process parameters according to the distribution of the residual stress field of the metal sheet after welding heat treatment.
FIG. 8 is a cloud of residual stress distributions after heat treatment. It can be seen that the residual stress peak after the heat treatment was reduced from 701.4MPa to 340.7MPa in consideration of the creep effect. Fig. 9 is a longitudinal residual stress distribution curve of the TC4 titanium alloy sheet after welding on the center line of the vertical weld and after heat treatment, and it can be seen that the longitudinal residual stress is a tensile stress with a higher value at the weld and the near-seam region, and is maximally close to 600MPa.
The invention can carry out numerical simulation analysis on the welding and heat treatment processes of the metal sheet to obtain the temperature field in the welding process and the distribution conditions of residual stress after welding and heat treatment, and provides a technical basis for predicting the residual stress in the welding process and the heat treatment process of the metal sheet in engineering.

Claims (4)

1. A method for improving a welding process of a metal sheet by predicting a welding heat treatment value of the metal sheet is characterized by comprising the following specific steps of:
the first step is as follows: establishing a thermodynamic coupling finite element analysis model in the metal sheet welding process:
establishing a metal sheet butt-joint laser welding model by using finite element software, selecting eight-node hexahedral units to divide grids of the metal sheet, and subdividing the grids near a welding seam;
setting thermophysical performance parameters of the metal material changing along with the temperature, namely the elastic modulus, the plastic curve, the thermal conductivity and the thermal expansion coefficient of the selected metal at different temperatures;
the second step is that: setting initial conditions and boundary conditions of a thermodynamic coupling finite element analysis model of a sheet metal welding process:
temperature boundary conditions: setting the welding environment temperature as room temperature, and setting boundary heat exchange condition parameters, namely heat exchange coefficients and heat radiation condition parameters; all the outer wall surfaces of the metal sheets are heat exchange surfaces;
structural boundary conditions: taking typical three-point constrained free deformation as a constraint condition, namely taking three continuous vertexes on the upper surface of a metal sheet, respectively constraining translational degrees of freedom in XYZ, YZ and Z directions, enabling the sheet to be free-deformed without rigid body movement, and loading a user-defined moving body heat source load;
the third step: establishing a welding heat source equation of the metal sheet:
establishing a double-ellipsoid heat source model, wherein the front half part and the rear half part of the heat source model are respectively an ellipsoid of 1/4, and the heat sources of the ellipsoid of the front half part and the ellipsoid of the rear half part are respectively distributed as follows:
Figure FDA0003758034860000011
Figure FDA0003758034860000012
wherein q is 1 Heat generation rate q of ellipsoid heat source for the first half 2 The heat generation rate of the ellipsoid heat source of the second half part; a is 1 、a 2 B and c are half-axis parameters of a double ellipsoid; i is welding current; u is welding voltage; eta is welding efficiency; f. of f As a function of the ellipsoidal heat distribution of the first half f r Is a second halfA partial ellipsoid heat distribution function; (x, y, z) are coordinates of the heat source central point in a global coordinate system of the finite element model;
the fourth step: calling a welding heat source equation of the metal sheet, carrying out numerical simulation on the welding process by combining a thermodynamic coupling finite element analysis model of the welding process of the metal sheet, carrying out heat transfer analysis based on a differential equation of heat transfer control,
the fifth step: taking the residual stress obtained by calculation in the welding process as an initial condition, and carrying out subsequent postweld heat treatment numerical simulation:
in the heat treatment and heat preservation stage, the softening effect and the creep effect of the material are considered, the material is cooled to room temperature by an air cooling method, the creep behavior of the metal conforms to the Norton creep rule, and the residual stress field distribution of the metal sheet after welding heat treatment is obtained after numerical simulation;
and a sixth step: and guiding to improve welding process parameters according to the distribution of the residual stress field of the post-welding heat treatment of the metal sheet.
2. The method of claim 1 for improving a welding process using a predicted sheet metal welding heat treatment value, comprising: in the third step, f f +f r ＝2。
3. The method of claim 1 for improving a welding process using a predicted sheet metal welding heat treatment value, comprising: in the fourth step, the heat transfer control differential equation is as follows:
Figure FDA0003758034860000021
wherein rho, c and lambda are the density, specific heat capacity and thermal conductivity of the metal sheet respectively;
Figure FDA0003758034860000022
the internal heat source intensity; and obtaining the temperature field and the stress field distribution in the welding process of the metal sheet after numerical simulation, wherein T is the temperature.
4. The method of claim 1 for improving a welding process using a predicted sheet metal welding heat treatment value, comprising: in the fifth step, the creep behaviour of the metal follows the Norton creep law:
Figure FDA0003758034860000023
wherein the content of the first and second substances,
Figure FDA0003758034860000024
for creep strain rate, σ is creep stress, n is stress index, A is material constant, Q is nominal creep activation energy, and T is temperature.
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