CN113139240A - Welding spot failure simulation method - Google Patents
Welding spot failure simulation method Download PDFInfo
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- CN113139240A CN113139240A CN202110489155.6A CN202110489155A CN113139240A CN 113139240 A CN113139240 A CN 113139240A CN 202110489155 A CN202110489155 A CN 202110489155A CN 113139240 A CN113139240 A CN 113139240A
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- 238000003466 welding Methods 0.000 title claims abstract description 46
- 238000004088 simulation Methods 0.000 title claims abstract description 27
- 238000000034 method Methods 0.000 title claims abstract description 21
- 239000002184 metal Substances 0.000 claims abstract description 23
- 239000000463 material Substances 0.000 claims abstract description 15
- 239000010953 base metal Substances 0.000 claims abstract description 7
- 229910000679 solder Inorganic materials 0.000 claims 1
- 230000007547 defect Effects 0.000 abstract description 3
- 238000004458 analytical method Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/10—Geometric CAD
- G06F30/15—Vehicle, aircraft or watercraft design
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- 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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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/08—Thermal analysis or thermal optimisation
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- Aviation & Aerospace Engineering (AREA)
- Computational Mathematics (AREA)
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- Mathematical Optimization (AREA)
- Pure & Applied Mathematics (AREA)
- Resistance Welding (AREA)
- Automobile Manufacture Line, Endless Track Vehicle, Trailer (AREA)
Abstract
The invention provides a welding spot failure simulation method, which comprises the following steps: A. determining the sizes and the lap joint relation of two welded sheet metal parts in a simulation model in finite element analysis software; B. determining the positions and the ranges of a welding nucleus area, a heat affected area and a base metal area according to an experimental scheme, and determining the shapes and the sizes of grids of the three areas; C. defining a weld nugget region as a rigid region; D. integrally defining two sheet metal parts as a thin shell unit, and defining material and attribute information of the sheet metal according to the information of the actual vehicle type; E. and determining boundary conditions, constraints, loads and the like in the simulation model, deriving and solving and calculating by using finite element analysis software. According to the scheme, the shell unit is adopted for modeling, the weld nucleus area does not need to be modeled separately, the heat affected area and the weld nucleus area do not need to be provided with failure plastic strain respectively, the model is established more conveniently, and the defect that the requirement on the precision of the previous weld nucleus area model is high is overcome.
Description
Technical Field
The invention relates to the technical field of automobile industrial simulation, in particular to a welding spot failure simulation analysis method.
Background
Spot welding is widely used in the automotive industry due to its advantages of light weight, high static strength, good reliability, stable performance, etc. The design of the automobile spot welding structure plays a vital role in automobile fatigue strength and collision safety. Resistance spot welding is a method of pressing a workpiece to be welded between two electrodes, applying current, and heating the workpiece to be welded to melt by resistance heat generated by the current flowing through a limited contact surface and an adjacent area of the workpiece to form an oblate nugget so as to achieve metal bonding. For a general low alloy steel plate, in a nugget area and a heat affected zone, due to the action of heat circulation and pressure, a microstructure is greatly changed from an original plate, namely, the material strength of the nugget area is greatly improved, and the performance of the heat affected zone is reduced. A large number of studies indicate that the failure behavior of the welding spot in the collision of the vehicle body is the phenomenon that the material of the heat affected zone of the welding spot tears along the whole circle around the weld nugget and the weld nugget keeps complete. Therefore, the finite element analysis of the strength of the resistance spot welding spot of the automobile body and the peripheral area thereof by the whole automobile manufacturing enterprise is very important, and the finite element analysis is mainly used for simulating the welding spot failure process in automobile collision, so that the design can be guided, and the cost can be greatly reduced.
Chinese patent CN101561840B discloses a numerical simulation method for spot welding connection and failure thereof, which uses a body grid and a shell grid to respectively establish a finite element model of a welding spot composed of a core welding area and a heat affected area, wherein the core welding area adopts a body unit, the heat affected area adopts a shell unit for modeling, and the heat affected area and the core welding area are respectively provided with failure plastic strain. In the Beam unit welding spot model in the prior art, the weld core area is prone to failure firstly, and the heat affected zone is not deformed obviously, which is contrary to the test result, and obviously, the model cannot simulate the welding spot failure. In the Tie contact welding spot model, because the welding nucleus area is provided with the binding contact, the material of the welding nucleus area is not correspondingly strengthened, so that the simulation of the failure of the welding spot by using the Tie contact welding spot model is inaccurate.
Disclosure of Invention
The invention aims to provide a welding spot failure simulation method which is simple and convenient to operate. A welding spot failure simulation method comprises the following steps: A. determining the sizes and the lap joint relation of two welded sheet metal parts in a simulation model in finite element analysis software; B. determining the positions and the ranges of a welding nucleus area, a heat affected area and a base metal area according to an experimental scheme, and determining the shapes and the sizes of grids of the three areas; C. defining a weld nugget region as a rigid region; D. integrally defining two sheet metal parts as a thin shell unit, and defining material and attribute information of the sheet metal according to the information of the actual vehicle type; E. and determining boundary conditions, constraints, loads and the like in the simulation model, deriving and solving and calculating by using finite element analysis software.
According to the scheme, the shell unit is adopted for modeling, the weld nucleus area does not need to be modeled separately, the heat affected area and the weld nucleus area do not need to be provided with failure plastic strain respectively, the model is established more conveniently, and the defect that the requirement on the precision of the previous weld nucleus area model is high is overcome. The model only needs to input the material elongation of the parent metal, and the maximum plastic strain of the heat affected zone is compared with the material elongation.
Drawings
Fig. 1 and 2 are schematic diagrams of two overlapping relationships.
Detailed Description
A welding spot failure simulation method comprises the following steps:
A. determining the sizes and the lap joint relation of two welded sheet metal parts in a simulation model in finite element analysis software;
B. determining the positions and the ranges of a welding nucleus area, a heat affected area and a base metal area according to an experimental scheme, and determining the shapes and the sizes of grids of the three areas;
C. defining a weld nugget region as a rigid region; (because the weld nucleus region between two sheet metal parts has the highest rigidity in the experimental process and is extremely difficult to damage, the weld nucleus region is set as a rigid region)
D. Integrally defining two sheet metal parts as a thin shell unit, and defining material and attribute information of the sheet metal according to the information of the actual vehicle type;
E. and determining boundary conditions, constraints, loads and the like in the simulation model, deriving and solving and calculating by using finite element analysis software.
In the experimental process, the weld nugget area between two sheet metal parts has the highest rigidity and is extremely difficult to damage, so that the weld nugget area is set as the rigid area to simplify the simulation process. According to the scheme, the shell unit is adopted for modeling, the weld nucleus area does not need to be modeled separately, the heat affected area and the weld nucleus area do not need to be provided with failure plastic strain respectively, the model is established more conveniently, and the defect that the requirement on the precision of the previous weld nucleus area model is high is overcome. The model only needs to input the material elongation of the parent metal, and the maximum plastic strain of the heat affected zone is compared with the material elongation.
The lap joint relationship in step a is "lap shear" and "cross stretch". These two overlapping relationships are two common solutions in the field of vehicle body welding.
The dividing steps of each area are as follows:
a. determining the position of a welding nucleus area according to an experimental scheme, and then determining the shape and the size of a grid of the welding nucleus area;
b. making a circle according to the diameter of the weld nugget and the position size of the weld nugget, and representing a weld nugget area in the simulation model;
c. performing two circles of washbhers outside the boundary of the weld nucleus area, wherein the area is a heat influence area in the model, and determining the shape and the size of a grid of the heat influence area;
d. and the areas except the welding nuclear area and the heat affected area are defined as metal plate base metal areas. The weld nugget region is the lap-jointed phase fusion region of the two metal plates. The heat affected zone is a non-overlapping zone with changed properties due to heating, and is usually in a bowl wall shape, the welding core zone is located at the bottom of the bowl, and the base metal zone is an unaffected original sheet metal part.
And the diameter of the welding core area is determined according to the actual diameter of the welding core or the average diameter of the welding process.
And E, judging that the test sample fails when the maximum plastic strain of the heat affected zone reaches the elongation of the material and comparing with the failure rate under the test condition.
And defining a weld nugget area as a circle with the diameter of 6mm, and outwards making two circles of washbhers with the grid size of 1mm on the boundary of the weld nugget area, wherein the area is a heat affected zone in the weld spot model, and other areas are base material areas.
And E, determining the load application direction according to the impact direction of the whole vehicle and the positions of the two sheet metal parts. This simulates the real load.
Table 1 experimental and simulation model weld failure force comparison:
Claims (7)
1. a welding spot failure simulation method is characterized by comprising the following steps:
A. determining the sizes and the lap joint relation of two welded sheet metal parts in a simulation model in finite element analysis software;
B. determining the positions and the ranges of a welding nucleus area, a heat affected area and a base metal area according to an experimental scheme, and determining the shapes and the sizes of grids of the three areas;
C. defining a weld nugget region as a rigid region;
D. integrally defining two sheet metal parts as a thin shell unit, and defining material and attribute information of the sheet metal according to the information of the actual vehicle type;
E. and determining boundary conditions, constraints, loads and the like in the simulation model, deriving and solving and calculating by using finite element analysis software.
2. The method for simulating a failure of a welding spot according to claim 1, wherein the overlapping relationship in the step A is "overlap shear" and "cross stretch".
3. The solder joint failure simulation method according to claim 1 or 2, wherein the dividing step of each area is:
a. determining the position of a welding nucleus area according to an experimental scheme, and then determining the shape and the size of a grid of the welding nucleus area;
b. making a circle according to the diameter of the weld nugget and the position size of the weld nugget, and representing a weld nugget area in the simulation model;
c. performing two circles of washbhers outside the boundary of the weld nucleus area, wherein the area is a heat influence area in the model, and determining the shape and the size of a grid of the heat influence area;
d. and the areas except the welding nuclear area and the heat affected area are defined as metal plate base metal areas.
4. The weld spot failure simulation method according to claim 1 or 2, wherein the diameter of the weld nugget area is determined according to the actual diameter of the weld nugget or the average diameter of the welding process.
5. The method for simulating failure of welding spots according to claim 1 or 2, wherein in step E, when the maximum plastic strain of the heat affected zone reaches the elongation of the material, the failure of the test sample is determined and compared with the failure rate under the test condition.
6. The weld joint failure simulation method according to claim 4, wherein the weld core area is defined as a circle with a diameter of 6mm, two circles of washbhers with a grid size of 1mm are formed outwards from the boundary of the weld core area, the area is a heat affected zone in the weld joint model, and the other areas are base material areas.
7. The welding spot failure simulation method according to claim 1 or 2, wherein in the step E, the load application direction is determined according to the impact direction of the whole vehicle and the positions of the two sheet metal parts.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202110489155.6A CN113139240A (en) | 2021-04-29 | 2021-04-29 | Welding spot failure simulation method |
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| CN202110489155.6A CN113139240A (en) | 2021-04-29 | 2021-04-29 | Welding spot failure simulation method |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117574739A (en) * | 2024-01-16 | 2024-02-20 | 湖南大学 | Fine numerical simulation method for warp defect welding spots |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101561840A (en) * | 2009-06-02 | 2009-10-21 | 肖锋 | Numerical value simulation method for spot welding connection and failure thereof |
| US20100052112A1 (en) * | 2008-04-03 | 2010-03-04 | Rogers John A | Printable, Flexible and Stretchable Diamond for Thermal Management |
| CN103796908A (en) * | 2011-08-10 | 2014-05-14 | 丰田自动车株式会社 | Front structure for vehicle |
| CN104573392A (en) * | 2015-01-27 | 2015-04-29 | 湖南大学 | Spot-weld fatigue life predicting method |
-
2021
- 2021-04-29 CN CN202110489155.6A patent/CN113139240A/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20100052112A1 (en) * | 2008-04-03 | 2010-03-04 | Rogers John A | Printable, Flexible and Stretchable Diamond for Thermal Management |
| CN101561840A (en) * | 2009-06-02 | 2009-10-21 | 肖锋 | Numerical value simulation method for spot welding connection and failure thereof |
| CN103796908A (en) * | 2011-08-10 | 2014-05-14 | 丰田自动车株式会社 | Front structure for vehicle |
| CN104573392A (en) * | 2015-01-27 | 2015-04-29 | 湖南大学 | Spot-weld fatigue life predicting method |
Non-Patent Citations (3)
| Title |
|---|
| 万鹏程;陈剑;: "利用CAE方法分析某客车整车共振问题", 噪声与振动控制, no. 01, pages 54 - 56 * |
| 李想;陈可明;: "某N_1类车辆安全带固定点强度对标及改进", 汽车工程学报, no. 02, pages 106 - 112 * |
| 陈军: "车身点焊特性及模型方法研究", 中国优秀硕士学位论文全文数据库, no. 2, pages 4 - 6 * |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117574739A (en) * | 2024-01-16 | 2024-02-20 | 湖南大学 | Fine numerical simulation method for warp defect welding spots |
| CN117574739B (en) * | 2024-01-16 | 2024-04-05 | 湖南大学 | Fine numerical simulation method for warp defect welding spots |
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