CN113435030A - Simulation analysis method for failure of welding spot - Google Patents
Simulation analysis method for failure of welding spot Download PDFInfo
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- CN113435030A CN113435030A CN202110699241.XA CN202110699241A CN113435030A CN 113435030 A CN113435030 A CN 113435030A CN 202110699241 A CN202110699241 A CN 202110699241A CN 113435030 A CN113435030 A CN 113435030A
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- G06F30/20—Design optimisation, verification or simulation
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- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/02—Reliability analysis or reliability optimisation; Failure analysis, e.g. worst case scenario performance, failure mode and effects analysis [FMEA]
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Abstract
The invention discloses a simulation analysis method for failure of a welding spot, which comprises the following steps: s1, carrying out a tensile test on the actual sample piece with the welding spot to obtain actual failure data; s2, establishing a welding spot simulation analysis model according to an actual sample piece, setting the size and the position of a welding spot according to the state of the welding spot on the actual sample piece, calibrating a material attribute curve of a thermal response area of the welding spot, wherein the material attribute curve of the thermal response area of the welding spot is a scaling strength curve and a fracture curve on the basis of the actual sample piece, and the scaling coefficient is 0.9-1.1; s3, performing simulation failure simulation to obtain simulation failure data, performing consistency comparison with actual failure data, if the simulation failure data are consistent, executing S4, and if the simulation failure data are inconsistent, adjusting the scaling coefficient to perform simulation failure again; and S4, inputting the obtained welding spot material parameters into the whole vehicle model, and carrying out whole vehicle analysis. The method can accurately simulate the welding spot area of the part, accurately predict the failure of the welding spot and facilitate the design change of the design area in the design stage.
Description
Technical Field
The invention relates to the technical field of vehicle simulation analysis, in particular to a simulation analysis method for failure of a welding spot.
Background
100% rigid barrier collision and 50% movable barrier offset collision are important investigation working conditions for evaluating the collision safety of the whole vehicle, and cracks of foot spaces caused by welding spot failure can be evaluated and corrected by-1 point, so that the C-NCAP performance is greatly influenced. In the middle-protected 25% rigid barrier collision working condition, welding spot failure exists at the root of the front longitudinal beam and the overlapping area of the passenger compartment, and the like, and the influence on the safety of the passenger compartment structure is large. However, in the current simulation analysis, the failure of the welding spot cannot be evaluated and predicted in the previous simulation because the welding spot is not designed to fail or simple force failure and time failure are adopted, which are greatly different from the actual working conditions.
CN112464401A discloses an accurate modeling method for a metal material welding spot, which is characterized in that the simulation parameters are adjusted by comparing the force and displacement curve of an actual welding spot sample with the force and displacement curve of CAE simulation, so that the simulation output curve is unified with the corresponding test curve, and a welding spot material parameter model is obtained and used in a complete vehicle simulation analysis model. In the method, the force and displacement curve is still adopted to carry out the simulation modeling of the failure of the welding spot, the simulation modeling is different from the actual failure mode of the welding spot, and the parameters of the welding spot need to be adjusted again after the thickness is changed.
Disclosure of Invention
The invention aims to provide a simulation analysis method for welding spot failure, which can accurately simulate a welding spot area of a part, accurately predict the failure of the welding spot and facilitate the design change of a design area in a design stage.
The simulation analysis method for the failure of the welding spot comprises the following steps:
s1, carrying out a tensile test on the actual sample piece with the welding spot to obtain actual failure data;
s2, establishing a welding spot simulation analysis model according to an actual sample piece, setting the size and the position of a welding spot according to the state of the welding spot on the actual sample piece, calibrating a material attribute curve of a thermal response area of the welding spot, wherein the material attribute curve of the thermal response area of the welding spot is a scaling strength curve and a fracture curve on the basis of the actual sample piece, and the scaling coefficient is 0.9-1.1;
s3, performing simulation failure simulation to obtain simulation failure data, performing consistency comparison on the simulation failure data and the actual failure data, if the simulation failure data and the actual failure data are consistent, executing S4, and if the simulation failure data and the actual failure data are not consistent, adjusting the scaling coefficient to perform the simulation failure simulation again;
and S4, inputting the obtained welding spot material parameters into the whole vehicle model, and carrying out whole vehicle analysis.
Further, in S3, if the simulated failure rate of the welding spot is 85-115% of the actual failure rate in the tensile test, and the tearing form of the welding spot simulated by the simulated failure is similar to the tearing form in the actual tensile test, it is determined that the simulated failure data is consistent with the actual failure data, otherwise, it is determined that the simulated failure data is inconsistent with the actual failure data.
Further, the tensile test in S1 is a shear tensile test, a cross tensile test or a peel tensile test.
According to the invention, by calibrating the material attribute curve of the thermal response area of the welding spot, the material attribute curve of the thermal response area of the welding spot is a scaling strength curve and a fracture curve on the basis of an actual sample, the scaling coefficient is 0.9-1.1, the failure of the thermal response area of the welding spot is increased, the failure mode is closer to the failure mode of the actual welding spot, the welding spot area of a part can be accurately simulated, the failure of the welding spot is accurately predicted, and the design change of the design area in the design stage is facilitated.
Drawings
FIG. 1 is a schematic flow diagram of the present invention;
FIG. 2 is a schematic diagram illustrating a simulation of shear-stretch failure of a solder joint according to an embodiment of the present invention;
FIG. 3 is a cross tensile failure simulation diagram of a welding spot according to a second embodiment of the present invention;
fig. 4 is a schematic diagram illustrating a simulation of a solder joint peel tensile failure according to a third embodiment of the present invention.
In the figure, 1-connector one, 11-thermally responsive zone one, 2-connector two, 21-thermally responsive zone two, 3-solder joint.
Detailed Description
The present application will be described in detail below with reference to the accompanying drawings.
In a first embodiment, referring to fig. 1, a simulation analysis method for solder joint failure includes the following steps:
and S1, carrying out a shear tensile test on an actual sample piece with welding points, wherein the actual sample piece comprises a first connecting piece and a second connecting piece which are fixedly connected through the welding points, and obtaining actual failure data.
S2, establishing a welding spot simulation analysis model in the preprocessing software according to the actual sample, referring to fig. 2, performing grid refinement on positions of the first connecting piece 1 and the second connecting piece 2 which need spot welding before the welding spot is established, wherein the grid length is 2mm, establishing connection information of the welding spot through a fine connection function, and generating a welding spot 3 through a connection manager. The welding spot 3 is a 4HEXAS solid welding spot, the diameter is set to be close to the average value of the actual welding spots, namely the diameter of the welding spot in the simulation analysis model is 6mm, and no failure is set. The method comprises the steps that a first thermal response area 11 is arranged in a circular ring area, close to a welding point 3, of a first connecting piece 1, the width of the circular ring area is 1mm, a second thermal response area 21 is arranged in a circular ring area, close to the welding point 3, of a second connecting piece 2, the width of the circular ring area is 1mm, material property curves of the first thermal response area 11 and the second thermal response area 21 of the welding point 3 are calibrated, the material property curve of the first thermal response area 11 is a scaling strength curve and a fracture curve on the basis of the first connecting piece 1, the scaling coefficient is 0.9, the material property curve of the second thermal response area 21 is a scaling strength curve and a fracture curve on the basis of the second connecting piece 2, the scaling coefficient is 0.9, and the first thermal response area 11 and the second thermal response area 21 adopt a No. 16 full integral form.
And S3, performing simulation failure simulation to obtain simulation failure data. The examination of welding spot failure, whether the welding spot fails can be directly observed in post-processing software through animation, when a thermal response area around the welding spot reaches a critical value, units of a first thermal response area 11 and a second thermal response area 21 can be automatically deleted, and at the moment, the thermal response area of the welding spot fails, and the welding spot has a falling risk; if the thermal response area unit around the welding spot is not deleted, the risk of welding spot falling off is small.
And comparing the consistency of the simulated failure data with the actual failure data, if so, executing S4, and if not, adjusting the scaling coefficient to perform the simulation failure simulation again.
And S4, inputting the obtained welding spot material parameters into the whole vehicle model, and carrying out whole vehicle analysis.
The second embodiment is a simulation analysis method for solder joint failure, which comprises the following steps:
and S1, performing a cross tensile test on an actual sample piece with welding spots, wherein the actual sample piece comprises a first connecting piece and a second connecting piece which are fixedly connected through the welding spots, and acquiring actual failure data.
S2, establishing a welding spot simulation analysis model in the preprocessing software according to the actual sample, referring to fig. 3, performing grid refinement on positions of the first connecting piece 1 and the second connecting piece 2 which need spot welding before the welding spot is established, establishing connection information of the welding spot through a define connection function, and generating the welding spot 3 through a connection manager. The welding spot 3 is a 4HEXAS solid welding spot, the diameter is set to be close to the average value of the actual welding spots, namely the diameter of the welding spot in the simulation analysis model is 6mm, and no failure is set. The method comprises the steps that a ring area, close to a welding point 3, of a first connecting piece 1, of the width of 1mm is a first thermal response area 11, a ring area, close to the welding point 3, of a second connecting piece 2, of the width of 1mm is a second thermal response area 21, material property curves of the first thermal response area 11 and the second thermal response area 21 of the welding point 3 are calibrated, the material property curve of the first thermal response area 11 is a scaling strength curve and a fracture curve on the basis of the first connecting piece 1, the scaling coefficient is 0.95, the material property curve of the second thermal response area 21 is a scaling strength curve and a fracture curve on the basis of the second connecting piece 2, the scaling coefficient is 0.95, and the first thermal response area 11 and the second thermal response area 21 adopt a 16-number full integral form.
And S3, performing simulation failure simulation to obtain simulation failure data. The examination of welding spot failure, whether the welding spot fails can be directly observed in post-processing software through animation, when a thermal response area around the welding spot reaches a critical value, units of a first thermal response area 11 and a second thermal response area 21 can be automatically deleted, and at the moment, the thermal response area of the welding spot fails, and the welding spot has a falling risk; if the thermal response area unit around the welding spot is not deleted, the risk of welding spot falling off is small.
And comparing the consistency of the simulated failure data with the actual failure data, if so, executing S4, and if not, adjusting the scaling coefficient to perform the simulation failure simulation again.
And S4, inputting the obtained welding spot material parameters into the whole vehicle model, and carrying out whole vehicle analysis.
In a third embodiment, a simulation analysis method for solder joint failure includes the following steps:
and S1, carrying out a peeling tensile test on an actual sample piece with welding spots, wherein the actual sample piece comprises a first connecting piece and a second connecting piece which are fixedly connected through the welding spots, and actual failure data are obtained.
S2, establishing a welding spot simulation analysis model in the preprocessing software according to the actual sample, referring to fig. 4, performing grid refinement on positions of the first connecting piece 1 and the second connecting piece 2 which need spot welding before establishing the welding spot, establishing connection information of the welding spot through a define connection function, and generating the welding spot 3 through a connection manager. The welding spot 3 is a 4HEXAS solid welding spot, the diameter is set to be close to the average value of the actual welding spots, namely the diameter of the welding spot in the simulation analysis model is 6mm, and no failure is set. The method comprises the steps that a first thermal response area 11 is arranged in a circular ring area, close to a welding point 3, of a first connecting piece 1, the width of the circular ring area is 1mm, a second thermal response area 21 is arranged in a circular ring area, close to the welding point 3, of a second connecting piece 2, the width of the circular ring area is 1mm, material property curves of the first thermal response area 11 and the second thermal response area 21 of the welding point 3 are calibrated, the material property curve of the first thermal response area 11 is a scaling strength curve and a fracture curve on the basis of the first connecting piece 1, the scaling coefficient is 1.1, the material property curve of the second thermal response area 21 is a scaling strength curve and a fracture curve on the basis of the second connecting piece 2, the scaling coefficient is 1.1, and the first thermal response area 11 and the second thermal response area 21 adopt a No. 16 full integral form.
And S3, performing simulation failure simulation to obtain simulation failure data. The examination of welding spot failure, whether the welding spot fails can be directly observed in post-processing software through animation, when a thermal response area around the welding spot reaches a critical value, units of a first thermal response area 11 and a second thermal response area 21 can be automatically deleted, and at the moment, the thermal response area of the welding spot fails, and the welding spot has a falling risk; if the thermal response area unit around the welding spot is not deleted, the risk of welding spot falling off is small.
And comparing the consistency of the simulated failure data with the actual failure data, if so, executing S4, and if not, adjusting the scaling coefficient to perform the simulation failure simulation again.
And S4, inputting the obtained welding spot material parameters into the whole vehicle model, and carrying out whole vehicle analysis.
The above description is only exemplary of the present application and should not be taken as limiting the present application, as any modification, equivalent replacement, or improvement made within the spirit and principle of the present application should be included in the protection scope of the present application.
Claims (3)
1. A simulation analysis method for failure of a welding spot is characterized by comprising the following steps:
s1, carrying out a tensile test on the actual sample piece with the welding spot to obtain actual failure data;
s2, establishing a welding spot simulation analysis model according to an actual sample piece, setting the size and the position of a welding spot according to the state of the welding spot on the actual sample piece, calibrating a material attribute curve of a thermal response area of the welding spot, wherein the material attribute curve of the thermal response area of the welding spot is a scaling strength curve and a fracture curve on the basis of the actual sample piece, and the scaling coefficient is 0.9-1.1;
s3, performing simulation failure simulation to obtain simulation failure data, performing consistency comparison on the simulation failure data and the actual failure data, if the simulation failure data and the actual failure data are consistent, executing S4, and if the simulation failure data and the actual failure data are not consistent, adjusting the scaling coefficient to perform the simulation failure simulation again;
and S4, inputting the obtained welding spot material parameters into the whole vehicle model, and carrying out whole vehicle analysis.
2. The simulation analysis method of solder joint failure according to claim 1, characterized in that: and in the step S3, if the simulation failure rate of the welding spot is 85-115% of the failure rate of the actual tensile test, and the tearing form of the simulation failure simulation welding spot is similar to that of the actual tensile test, judging that the simulation failure data is consistent with the actual failure data, otherwise, judging that the simulation failure data is inconsistent with the actual failure data.
3. The simulation analysis method of solder joint failure according to claim 1, characterized in that: the tensile test in S1 is a shear tensile test, a cross tensile test or a peel tensile test.
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| CN202110699241.XA CN113435030A (en) | 2021-06-23 | 2021-06-23 | Simulation analysis method for failure of welding spot |
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| CN202110699241.XA CN113435030A (en) | 2021-06-23 | 2021-06-23 | Simulation analysis method for failure of welding spot |
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Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108595898A (en) * | 2018-06-13 | 2018-09-28 | 上汽大众汽车有限公司 | Finite element modeling method based on vehicle collision simulation and system |
| CN109117569A (en) * | 2018-08-24 | 2019-01-01 | 上汽大众汽车有限公司 | Collision finite element model modeling method with octagon spot welding heat-affected zone structure |
| CN112182927A (en) * | 2020-09-15 | 2021-01-05 | 西北工业大学 | Method for simulating mutual influence of cracks of high-temperature alloy linear friction welding joint |
| CN112464401A (en) * | 2020-11-24 | 2021-03-09 | 一汽奔腾轿车有限公司 | Accurate modeling method for metal material welding spot |
-
2021
- 2021-06-23 CN CN202110699241.XA patent/CN113435030A/en not_active Withdrawn
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN108595898A (en) * | 2018-06-13 | 2018-09-28 | 上汽大众汽车有限公司 | Finite element modeling method based on vehicle collision simulation and system |
| CN109117569A (en) * | 2018-08-24 | 2019-01-01 | 上汽大众汽车有限公司 | Collision finite element model modeling method with octagon spot welding heat-affected zone structure |
| CN112182927A (en) * | 2020-09-15 | 2021-01-05 | 西北工业大学 | Method for simulating mutual influence of cracks of high-temperature alloy linear friction welding joint |
| CN112464401A (en) * | 2020-11-24 | 2021-03-09 | 一汽奔腾轿车有限公司 | Accurate modeling method for metal material welding spot |
Non-Patent Citations (1)
| Title |
|---|
| 杨济匡等: "实体单元焊点模型在前纵梁碰撞仿真中的应用", 《吉林大学学报(工学版)》 * |
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