CN115238558A - High-precision aluminum alloy welding joint temperature field simulation prediction method - Google Patents
High-precision aluminum alloy welding joint temperature field simulation prediction method Download PDFInfo
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Abstract
The invention discloses a high-precision aluminum alloy welding joint temperature field simulation prediction method, which is compared with the prior art, before finite element modeling, a simple welding seam measurement test method is adopted, the welding seam length is measured, and welding seam appearance parameters of the welding joint, such as the welding seam width, the welding seam depth and the welding toe depth of a rib plate and a wall plate, are calibrated in detail. The detailed dimension profile height reduction of the welding seam is applied to a simulation model, and the shape calibration precision of a welding simulation heat source and a test welding seam reaches over 88 percent. The dynamic process of heat source movement in the welding process is presented to a high degree in simulation calculation, the problem that the heat source model movement is inaccurate in welding simulation analysis is avoided, accurate description of the distribution of the temperature field of the welding joint is achieved, and the simulation prediction accuracy of the transverse direction and the longitudinal direction of the welding temperature field can reach more than 95%.
Description
Technical Field
The invention relates to the technical field of metal material connection performance analysis, in particular to a high-precision aluminum alloy welding joint temperature field simulation prediction method.
Background
Aluminum alloys are widely used in the automotive industry because of their high specific strength, light weight, good formability, excellent extrudability, and other characteristics. As one of main connection modes of an automobile body, an aluminum alloy welding technology is a premise for realizing large-scale application of aluminum alloy structural parts of a new energy automobile. However, due to the special physical characteristics of the welding process, such as complex physicochemical reaction, high heat conduction efficiency of the aluminum alloy, etc., the prediction of the welding temperature field of the aluminum alloy becomes extremely difficult. At present, the prediction of the conventional aluminum alloy welding temperature field mainly depends on a large amount of test data, and curve fitting is carried out on the basis of the test data to establish an empirical model. Therefore, in the aluminum alloy welding process, the invention of an accurate prediction method of the welding temperature field is needed.
Nowadays, the welding finite element numerical analysis method is widely applied to engineering application. By welding numerical simulation software, the test times can be effectively reduced, the time is saved, the cost is reduced, and technical guidance and theoretical basis are provided for actual production. The existing certain commercial software is special software for welding simulation analysis, the interface operation is humanized, and all instruction operations can be carried out by dragging the required model and corresponding physical data into a process tree by using a mouse for application. The software user interface is intuitive in operation and quick in response, and can effectively help CAE engineers to save research and development cost, so that the software user interface is widely applied to the field of automobile industry.
At present, in the simulation analysis of aluminum alloy welding, most CAE engineers set the on-site welding process parameters in welding software, such as welding current, voltage, welding speed and the like. However, the setting of the ellipsoid parameters of the welding heat source is usually a default value, and the detailed weld morphology parameter values of the joint are rarely calibrated on the welding site through the size of a section weld. Therefore, the moving mode and the temperature conduction of the welding heat source are inconsistent with the actual situation, so that the accuracy of a welding simulation analysis result is low, and the distribution of the aluminum alloy welding temperature field cannot be accurately predicted.
Disclosure of Invention
The invention aims to solve the problems of the background technology and provides a high-precision aluminum alloy welding joint temperature field simulation prediction method.
The purpose of the invention can be realized by the following technical scheme:
a high-precision aluminum alloy welding joint temperature field simulation prediction method comprises the following steps:
s1: preparing a welding test plate, and acquiring a real-time temperature curve of a welding test plate wall plate and a rib plate by adopting a galvanic couple;
s2: intercepting a weld sample, and preparing a weld appearance sample by adopting grinding equipment;
s3: selecting a penetration testing device to observe the arc-closing length and the cross-sectional shape of the welding seam of the joint, and carrying out detailed size calibration on the shape of the welding seam of the joint by using image processing software:
s4: establishing a three-dimensional assembly model of a test plate and a welding tool through three-dimensional software modeling, and importing finite element pretreatment software for detailed grid division;
s5: detecting chemical components of the aluminum alloy, and then introducing material performance simulation software to calculate to obtain a curve of the aluminum alloy material parameters changing along with the temperature;
s6: importing the finite element mesh model obtained in the step S4 into welding finite element analysis software; importing the thermal physical property parameter curve of the aluminum alloy material obtained in the step S5 into a software material library, and defining material attributes and boundary conditions of a test panel and a tool;
s7: selecting a double-ellipsoid heat source model as a welding simulation heat source;
s8: setting the actual values of the welding seam shape parameters measured in the S4 in software;
s9: a set is established for the welding heat source moving track node, and a welding heat source moving track is defined;
s10: establishing a welding temperature field monitoring node;
s11: selecting a transient solver to perform welding temperature field simulation calculation;
s12: and outputting a calculation result.
As a further scheme of the invention: the galvanic couple is K-type galvanic couple.
As a further scheme of the invention: and in S8, the actual values of the welding seam appearance parameters measured in S4, such as the length of the welding seam of the joint, the width of the welding seam, the depth of the welding seam and the overall contour of the welding seam.
As a further scheme of the invention: the heat source model distribution function in S7 is:
the expression of the front semi-ellipsoid heat source:
latter half ellipsoid heat source expression:
q is the instantaneous welding heat of the heat source, a, b, cf and cr are heat source shape parameters, and f1 and f2 are energy distribution coefficients of front and rear ellipsoids of the heat source model respectively.
The invention has the beneficial effects that:
compared with the prior art, the high-precision aluminum alloy welding joint temperature field simulation prediction method disclosed by the invention has the advantages that before finite element modeling, a simple welding seam measurement test method is adopted, the welding seam length is measured, and welding seam appearance parameters of the welding joint, such as the welding seam width, the welding seam depth and the welding toe depth of a rib plate and a wall plate, are calibrated in detail. The detailed dimension profile height reduction of the welding seam is applied to a simulation model, and the shape calibration precision of a welding simulation heat source and a test welding seam reaches over 88 percent. The dynamic process of heat source movement in the welding process is presented to a high degree in simulation calculation, the problem of inaccurate heat source model movement in welding simulation analysis is avoided, accurate description of welding joint temperature field distribution is realized, and the transverse and longitudinal simulation prediction accuracy of a welding temperature field can reach more than 95%.
Drawings
The invention will be further described with reference to the accompanying drawings.
FIG. 1 is a weld profile parameter map of the present invention;
FIG. 2 is a graph of the thermophysical parameters of the material of the invention as a function of temperature;
FIG. 3 is a dual ellipsoid heat source model of the present invention;
FIG. 4 is a comparison of temperature change curves for weld simulation and test monitoring points in accordance with the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1-4, the present invention is a high-precision simulation method for predicting the temperature field of an aluminum alloy welded joint,
s1: preparing a T-shaped welding test plate by using an automatic welding robot working platform, and collecting a real-time temperature curve of the welding test plate by using a K-shaped thermocouple;
the test plate is polished to metallic luster before the test, and the T-shaped test plate is fixed through the welding tool which is arranged independently. A drill bit with the diameter of 1mm is adopted to drill holes in the areas of the test plate wall plate and the rib plate, so that K-type thermocouple temperature monitoring points can be conveniently arranged, and real-time temperature curve collection is carried out on a welding temperature field.
S2: intercepting a weld sample at the middle part of the T-shaped joint, and grinding by adopting a grinder to prepare a weld appearance sample;
cutting out a welding seam sample by adopting a wire cut electrical discharge machine, and grinding by using 600-mesh, 100-mesh and 2000-mesh abrasive paper through a grinding machine to prepare a welding seam appearance sample;
s3: observing the shape of the section of the welding seam by using a fusion depth measuring device, and carrying out detailed dimension calibration on the shape of the welding seam by using image processing software;
and (4) importing the observed welding seam section morphology picture into image processing software, firstly entering an option to calibrate the T-shaped corner joint, and determining that the welding seam size is correct. Enter the measurement interface to confirm the unit of measurement, arrow type, color, and line type. And selecting a measurement mode to calibrate the length of the section of the welding seam, the width of the welding seam, the depth of the welding seam, and the size of the rib plate and the weld toe of the wall plate in detail respectively. And (5) exporting and storing the welding seam appearance picture after the welding seam appearance picture is measured.
S4: establishing a T-shaped test plate and welding tool assembly model and a T-shaped joint welding seam section model through three-dimensional software modeling, and introducing finite element pretreatment software for detailed meshing;
establishing a three-dimensional model through software, importing finite element preprocessing software for detailed grid division, and selecting hexahedral grids for model division. Different parts are built according to the distribution of the welding heat influence zones, grids are divided in a density mode, the grid size is smaller as the grids are closer to a welding seam, the minimum grid size is divided into 1mm multiplied by 1mm, the total number of nodes is 77842, and the total number of units is 52328.
S5: detecting chemical components of the aluminum alloy, and then introducing material performance simulation software to calculate to obtain a temperature variation curve of the parameters of the aluminum alloy material;
cutting the aluminum alloy material into small pieces, putting the small pieces into a beaker, pouring the solution into the beaker, and detecting the solution by using a plasma atomic emission spectrometry to obtain the chemical components of the aluminum alloy. Inputting aluminum alloy chemical components into material performance simulation software, and obtaining an aluminum alloy material parameter variation curve along with temperature through calculation;
s6: importing the finite element mesh model obtained in the step S4 into welding finite element analysis software; and (4) importing the thermophysical property parameter curve of the aluminum alloy material obtained in the step (5) into a software material library, and defining the material properties and boundary conditions of the test panel and the tool.
And (4) exporting the finite element mesh model from the finite element preprocessing software, storing, importing the finite element mesh model into the welding finite element analysis software, and dragging the finite element mesh model into different parts one by one. And (4) importing the thermophysical parameter curve of the aluminum alloy material into a software material library, establishing a new material attribute and endowing the new material attribute to the welding test plate. And restoring and defining boundary conditions of the test board and the tool as far as possible according to the environment of the welding site.
S7: a double-ellipsoid heat source model is selected as a welding simulation heat source, and the distribution function of the heat source model is as follows:
the expression of the front semi-ellipsoid heat source:
latter half ellipsoid heat source expression:
q is the instantaneous welding heat of the heat source, a, b, cf and cr are heat source shape parameters, and f1 and f2 are energy distribution coefficients of front and rear ellipsoids of the heat source model respectively;
s8: setting the detailed weld appearance parameter values measured in the step S4, such as weld width, weld depth and weld outline, in the heat source parameters of the welding software;
and entering a welding software heat source parameter setting interface, and reducing the shape parameters of the welding heat source as much as possible according to the detailed shape parameter values of the welding seam.
S9: a set is established for the welding heat source moving track node, and a welding heat source moving track is defined;
and (4) newly building a node set in the welding software set block, defining a moving track of a welding heat source, and moving the welding heat source from the arc starting to the arc starting position on the surface of the grid.
S10: establishing a welding temperature field monitoring node, and conveniently deriving a simulation result after completing calculation;
and (4) newly building a node set in the welding software set block, and respectively detecting the node temperatures of the arc starting area, the middle area and the arc ending area which are 5mm, 10mm, 15mm and 20mm away from the fusion line.
S11: selecting a transient solver to perform welding temperature field simulation calculation;
and selecting a transient solver, carrying out thermal calculation on the model, and carrying out welding simulation calculation according to the configuration of the server.
S12: and outputting a calculation result.
And checking the result in the welding software, and checking the welding simulation temperature distribution cloud picture by double clicking the temperature area adjustment color legend. Clicking a result area, entering a welding monitoring block, and checking the real-time dynamics of a welding simulation heat source. And (3) utilizing image processing software to calibrate the appearance of the cross section of the welding seam of the simulated heat source, and comparing the obtained result with the actual appearance parameter value of the welding seam, as shown in table 1.
The result shows that according to the standard GMW-14058, simulation and test results both accord with the standard, the simulation modeling weld morphology parameter and the test alignment precision both reach more than 88%, and the welding heat source weld morphology parameter is proved to be reasonably selected.
TABLE 1 simulation and test weld section morphology measurement results
Clicking a tracking point, entering a result display block, exporting the simulation calculation result data of the welding temperature field, and performing benchmarking on simulation and test data in data processing software.
By comparing the results of transverse simulation calculation and longitudinal simulation calculation and test of the welding temperature field, the temperature rise speed, the peak temperature and the cooling time of the temperature curve are well matched, the simulation precision reaches more than 95%, and the detailed temperature values of the simulation and test welding temperature field are shown in a table 2.
TABLE 2 detailed temperature values of simulation and test welding temperature field
The invention needs to be described with reference to the accompanying drawings for the mechanical product invention, the mutual position relation and the assembly connection relation among all parts or circuit components, and the functions of all parts; the working principle and the process are described by combining the drawings and the actions of all parts, namely the static description is made in the front, and the dynamic description is made in the back.
The invention calibrates the detailed parameters of the welding seam appearance of the welding joint, such as the characteristics of the width of the welding seam, the depth of the welding seam, the welding toe of the rib plate and the wall plate and the like, by a simple penetration measuring instrument test method. In simulation, the alignment precision of the appearance of the welding seam and the test reaches more than 88%, and the dynamic process of movement of a welding heat source is highly reduced to a higher degree, so that the prediction precision of a welding temperature field reaches more than 95%. Compared with the prior art, the method has the following advantages:
advantage 1: the method utilizes the penetration measuring instrument and the image processing software to calibrate the welding seam morphology parameters in detail, and has the advantages of simple measuring equipment, reliable method, high efficiency and the like;
advantage 2: according to the method, the detailed sizes of the width of the welding seam, the depth of the welding seam, the rib plate, the welding toe of the wall plate and the like are applied to a simulation model, the alignment precision of the appearance and the test of the welding seam in the simulation is 88%, and the transverse and longitudinal prediction precision of a welding temperature field is more than 95%;
advantage 3: the method can predict the temperature distribution of the welding heat affected zone with high efficiency and high precision, thereby accurately researching the attenuation influence of the welding heat impact on the aluminum alloy heat affected zone, avoiding the need of carrying out a temperature field monitoring test and effectively reducing the test workload;
advantage 4: the method can also provide theoretical reference for the high-efficiency and high-precision prediction of the temperature field of the welding joint of other metal materials.
Although one embodiment of the present invention has been described in detail, the description is only for the purpose of illustrating the preferred embodiments of the present invention and should not be taken as limiting the scope of the invention. All equivalent changes and modifications made within the scope of the present invention shall fall within the scope of the present invention.
Claims (4)
1. A high-precision aluminum alloy welding joint temperature field simulation prediction method is characterized by comprising the following steps:
s1: preparing a welding test plate, and acquiring a real-time temperature curve of a welding test plate wall plate and a rib plate by adopting a galvanic couple;
s2: intercepting a weld sample, and preparing a weld appearance sample by adopting grinding equipment;
s3: selecting a penetration testing device to observe the arc-closing length and the welding seam section appearance of the joint, and performing detailed dimension calibration on the welding seam appearance of the joint by using image processing software:
s4: establishing a three-dimensional assembly model of a test plate and a welding tool through three-dimensional software modeling, and importing finite element pretreatment software for detailed grid division;
s5: detecting chemical components of the aluminum alloy, and then introducing material performance simulation software to calculate to obtain a temperature variation curve of the parameters of the aluminum alloy material;
s6: importing the finite element mesh model obtained in the step S4 into welding finite element analysis software; importing the thermal physical property parameter curve of the aluminum alloy material obtained in the step S5 into a software material library, and defining material attributes and boundary conditions of a test panel and a tool;
s7: selecting a double-ellipsoid heat source model as a welding simulation heat source;
s8: setting the actual values of the welding seam shape parameters measured in the S4 in software;
s9: establishing a set for the welding heat source movement track nodes, and defining the welding heat source movement track;
s10: establishing a welding temperature field monitoring node;
s11: selecting a transient solver to perform welding temperature field simulation calculation;
s12: and outputting a calculation result.
2. The high-precision aluminum alloy welded joint temperature field simulation prediction method according to claim 1, characterized in that the galvanic couple is a K-type galvanic couple.
3. A high-precision aluminum alloy welded joint temperature field simulation prediction method according to claim 1, characterized in that in S8, actual values of weld profile parameters measured in S4, such as joint weld length, weld width, weld depth and overall weld profile, are used.
4. The high-precision aluminum alloy welded joint temperature field simulation prediction method as claimed in claim 1, wherein the heat source model distribution function in S7 is:
the expression of the front semi-ellipsoid heat source:
latter half ellipsoid heat source expression:
q is the instantaneous welding heat of the heat source, a, b, cf and cr are heat source shape parameters, and f1 and f2 are energy distribution coefficients of front and rear ellipsoids of the heat source model respectively.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116011221A (en) * | 2022-12-31 | 2023-04-25 | 华中科技大学 | Method and system for rapidly checking welding heat source model parameters based on welding morphology |
| CN116423005A (en) * | 2023-06-14 | 2023-07-14 | 苏州松德激光科技有限公司 | Tin soldering process optimization method and system for improving welding precision |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116011221A (en) * | 2022-12-31 | 2023-04-25 | 华中科技大学 | Method and system for rapidly checking welding heat source model parameters based on welding morphology |
| CN116011221B (en) * | 2022-12-31 | 2023-09-29 | 华中科技大学 | Method and system for rapidly checking welding heat source model parameters based on welding morphology |
| CN116423005A (en) * | 2023-06-14 | 2023-07-14 | 苏州松德激光科技有限公司 | Tin soldering process optimization method and system for improving welding precision |
| CN116423005B (en) * | 2023-06-14 | 2023-10-31 | 苏州松德激光科技有限公司 | Tin soldering process optimization method and system for improving welding precision |
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