JP7328516B2 - Welded Joint Fracture Prediction Method by Spot Welding, Welded Joint Fracture Prediction Program by Spot Welding, and Welded Joint Fracture Prediction Device by Spot Welding - Google Patents

Description

The present invention relates to prediction of fracture of a welded joint by spot welding, and more particularly to prediction of fracture of a welded joint by spot welding performed by finite element method (hereinafter sometimes referred to as "FEM") analysis.

Resistance spot welding (hereinafter sometimes referred to as "spot welding") is widely used as a method of joining steel plates, which is typified, for example, in automobile assembly processes.
In a member assembled by spot welding, for example, in a collision energy absorption member, if the weld nugget diameter or welding position (spot position) is not appropriate, the welded portion will break during the collision deformation of the assembled member, and the absorption will originally occur. It may not be possible to absorb the energy it should have, so performance evaluation is important.

Conventionally, FEM analysis is often used to evaluate the collision energy absorption performance of members, but there is a demand for a more accurate evaluation. In order to improve the analysis accuracy, it is important to predict the mode of fracture of the weld zone, and based on this, it is required to obtain welding conditions for preventing the occurrence of fracture.

Non-Patent Literature 1 discloses a technique relating to a fracture prediction method for spot welds intended for steel plates for automobiles. According to this, it is considered possible to accurately predict the joint strength and fracture mode for arbitrary plate assemblies with different load modes to the weld.
However, in this technique, the shape of the weld nugget (weld) and heat-affected zone (hereinafter sometimes referred to as "HAZ") is modeled from the cross section of the welded part obtained by experiment, and the fracture criterion is also obtained by experiment. , requiring a lot of manual intervention. Also, since the residual stress due to welding is not considered, the initial state of the analytical model to be evaluated differs from the actual situation.

Patent Literature 1 discloses a method of estimating a fracture criterion of an evaluation target material from a plurality of previously derived fracture criteria by an approximate expression using the chemical composition of the material as a parameter.
However, the method for estimating the shape of the weld is not described here. Also, the residual stress due to welding is not considered.

Patent Literature 2 describes a crack propagation prediction method based on a stress intensity factor K in consideration of thermal strain from welding temperature or residual stress obtained by the intrinsic stress method.
However, here, the welding temperature estimation from the welding conditions is not analyzed, and the influence of the shape after welding is not taken into consideration. In addition, the critical plastic strain considering the effect of stress triaxiality is not applied to the prediction of crack growth, and it does not correspond to any loading mode.

Patent Literature 3 describes a method for judging breakage of spot welds using the finite element method.
However, this method does not describe a method for estimating the weld shape.

Patent Literature 4 describes a method of simulating resistance spot welding using the finite element method to predict post-weld hardness.
However, this method cannot predict the joint strength and fracture mode when a tensile load is applied to the welded joint.

Non-Patent Document 2 describes a method of estimating fracture stress, and is said to be able to consider the influence of residual stress.
However, this method is a simple method based on a numerical prediction model and is not a method using thermal elastic-plastic FEM analysis.

Non-Patent Document 3 describes an FEM analysis technique for welding deformation and residual stress.
However, this method relates to arc welding and does not mention post-welding fracture prediction.

Non-Patent Document 4 describes a technique in which welding FEM analysis is used to predict fatigue crack growth.
However, this method does not apply critical plastic strain considering the effect of stress triaxiality to predict crack growth, and does not support arbitrary loading modes.

Ueda et al., "Study of Spot Weld Fracture Prediction Technology Considering Stress Triaxiality (First Report)", Transactions of Society of Automotive Engineers of Japan, Vol. 44, No. 2, p727 (2013) Mimura et al., "Simple Estimation Method of Influence of Residual Stress on Fracture Stress", Pressure Technical Papers, Vol. 41, No. 2, p48 Asa et al., "Thermal-elastic-plastic analysis technique for welding deformation by explicit FEM", Light Metal Welding Papers, Vol. 46, No. 4, p142 (2008) "Analysis Tool for Fatigue Crack Propagation in Welds", 12th Lecture Meeting (2019) hosted by International Collaborative Welding Computational Science Research Center Ueda et al., "Spot Welding Simulation for Automobile Steel Plates", Nippon Steel Technical Report, No. 409, p108 (2017) Kawaraki et al., "Effect of Implicit Integration in Quenching Residual Stress Analysis Including Transformation Plasticity and Kinematic Hardening," Nippon Steel Technical Report, No. 410, p57 (2018)

JP 2015-17817 A JP 2008-292206 A JP 2010-127933 A JP 2017-013078 A

The present invention provides a fracture prediction method for welded joints by spot welding that can improve the accuracy of fracture prediction in spot welding. In addition, there are provided a program for predicting breakage of a welded joint by spot welding and a device for predicting breakage of a welded joint by spot welding.

If the inventors construct an analysis model for fracture prediction simulation of spot welded joints that reflects the numerical analysis simulation results of the spot welding process, the indentation by the electrode, the shape of the welding nugget and HAZ, and the residual stress due to welding can be considered. It was conceived that an appropriate analysis model corresponding to the actual situation could be constructed, and the present invention was completed by embodying this idea. The present invention will be described below.

One aspect of the present invention is a method for predicting fracture of a welded joint due to spot welding using numerical analysis, in which calculation is performed to obtain the shape of the weld and the stress distribution in the thickness direction in the weld. This is a fracture prediction method for welded joints, in which a model is created from welded joint shape data including the shape and stress distribution obtained by calculation, and stress analysis is performed using the model.

Determination of rupture is performed by including a rupture criterion in the model, and the rupture criterion can be obtained in advance based on a micro-tensile test and FEM analysis results simulating this.

Another aspect of the present invention is a program for predicting fracture of a welded joint due to spot welding, comprising: a step of calculating a shape of a weld and a stress distribution in the thickness direction of the weld; and a step of forming a model based on shape data of the welded joint including the stress distribution, and a step of performing stress analysis using the model.

Another aspect of the present invention is a device for predicting fracture of a welded joint due to spot welding, comprising storage means storing a program, computing means for performing computation based on the program, and a result computed by the computing means. and a display means for displaying the shape of the welded joint and the shape data of the welded joint including the shape and stress distribution obtained by the calculation for obtaining the shape of the weld and the stress distribution in the thickness direction of the weld. It is a fracture prediction device for welded joints that performs calculations for creating a model by and calculations for stress analysis using the model.

ADVANTAGE OF THE INVENTION According to this invention, the accuracy of the fracture|rupture prediction of the welded joint by spot welding can be made favorable.

FIG. 4 is a schematic diagram for explaining a scene of spot welding and a molten nugget formed at this time; It is a figure explaining the flow of fracture|rupture prediction method S10 of a welded joint. FIG. 5 is a diagram illustrating a specific example of welding process calculation S11; It is a figure explaining the shape of the welding part of welding process calculation S11. It is a figure explaining structure|tissue distribution of welding process calculation S11. It is a figure explaining thickness direction stress distribution of welding process calculation S11. It is a figure explaining model creation S12 for fracture analysis. It is a figure explaining the characteristic obtained beforehand. It is a figure explaining the boundary conditions in the specific example of fracture|rupture prediction calculation S13. It is a figure explaining a stress-analysis result. It is a figure which compares the difference between an actual tensile test and the prediction by this form. FIG. 2 is a diagram illustrating the configuration of a welded joint fracture prediction device 30 ;

FIG. 1 is a cross-sectional view schematically showing a scene of spot welding and a welded portion during spot welding. Here, two steel plates 2 and 3 are superimposed, sandwiched between two electrodes 1 from one side and the other side, and spot-welded. Here, the portion indicated by A in FIG. 1 is the melted portion (melted nugget). This melted portion solidifies to form a welded portion (bonded portion), which joins the two steel plates.
Such spot welding itself is well-known, and a plurality of materials to be welded are superimposed, sandwiched between two electrodes, and energized while being pressed. The embodiment described below relates to prediction of breakage of a member having such joints by spot welding, using a simulation based on numerical analysis.

FIG. 2 shows a flow of a fracture prediction method S10 of a welded joint by spot welding according to one embodiment (hereinafter sometimes referred to as "fracture prediction method S10").
As can be seen from FIG. 2, the fracture prediction method S10 includes welding process calculation S11, fracture analysis model creation S12, and fracture prediction calculation S13.

In the welding process calculation S11, FEM analysis mesh data divided into minute elements of an appropriate size is created from the combination of plates to be evaluated and the shape of the electrode, and material property data, welding conditions, boundary conditions, etc. are set. welding simulation.
Such welding simulation can use general-purpose numerical analysis software or a self-made numerical analysis program, and is not particularly limited, but in this embodiment, the following simulation is performed.

In this embodiment, for example, as described in Non-Patent Document 5, electric field-temperature field coupled analysis and temperature field-stress field coupled analysis corresponding to the electric heating process of spot welding are performed to obtain the shape of the weld. can be done. Thereby, the shapes of the welded portion and the HAZ after spot welding are completed can be obtained. In addition, in accordance with this, for example, as described in Non-Patent Document 6, a temperature field-stress field coupled analysis corresponding to the cooling process and considering phase transformation is performed, and the stress distribution in the plate thickness direction of the weld is calculated. Obtainable.
Therefore, by combining the simulation result of the welded portion shape and the result of the stress distribution of the welded portion, it is possible to obtain the stress distribution corresponding to the residual stress in the welded portion after the completion of spot welding. The resulting weld geometry, texture distribution, and stress distribution are then preserved. This storage is performed by writing the obtained results into a memory of a computer (for example, a computing device 30 described later), a hard disk, or a medium such as a CD-ROM, which is an external storage medium.

The welding process calculation S11 will be described more specifically with an example as follows. FIG. 3 shows an FEM analysis mesh 10 modeling the board assembly and electrodes to be evaluated. Here, each analysis mesh of the upper electrode 11, the lower electrode 12, the upper steel plate 13, and the lower steel plate 14 appears.
In this example, the object to be evaluated is a 590 MPa grade steel plate (thickness: 1.6 mm) with a length of 50 mm.
Then, mechanical property data, thermophysical property data, and other material property data corresponding to this material were set. Here, the mechanical property data are Young's modulus, Poisson's ratio, and deformation resistance curve, the thermophysical property data are specific heat, thermal conductivity, and linear expansion coefficient, and the other material property data are electrical resistivity, density, and transformation expansion. coefficient, transformation plasticity coefficient, and latent heat of phase transformation.
As welding conditions, the pressure applied to the electrode, the current applied to the electrode, the energization time, the holding time, and the frequency were set.

Under the above conditions, coupled analysis of the electric field-temperature field, coupled analysis of the temperature field-stress field, and coupled analysis of the temperature field-stress field corresponding to the cooling process and considering the phase transformation were performed. Ta.
FIG. 4 shows the liquid phase distribution in the vicinity of the fusion zone (the upper electrode 11 and the lower electrode 12 are excluded). Here, the portion having a liquid phase rate of 0.8 or more is defined as the welded metal portion 15, and this portion becomes the welded portion (bonded portion), and can be considered to join the two steel plates.
FIG. 5 shows the respective martensite volume fraction distributions (the upper electrode 11 and the lower electrode 12 are excluded). Here, the portion 16 with a martensite volume fraction of 0.9 or more is displayed in white.
FIG. 6 shows the plate thickness direction stress distribution (the upper electrode 11 and the lower electrode 12 are excluded). The unit is MPa. This plate thickness direction stress distribution corresponds to the residual stress of the weld zone after welding.
These analysis result data are stored in a hard disk (storage means).

Returning to FIG. 2, the fracture analysis model creation S12 will be described. In fracture analysis model creation S12, a welded joint shape model is created from the weld shape saved in welding process calculation S11. This welded joint shape model is created from a joint type database consisting of sheet width, length, and corner R size, or joint type information that is sequentially input.
When the above-described welding process calculation S11 is performed using a three-dimensional model, the weld shape and plate thickness direction stress distribution saved in the welding process calculation S11 can be applied as they are to the welded joint shape model.
On the other hand, when the welding process analysis S11 described above is performed using a two-dimensional axisymmetric model, the shape of the weld and the plate thickness direction stress distribution are copied in the circumferential direction and applied to the welded joint shape model.

The fracture criterion εB of the base material, the fracture criterion εH of the HAZ, and the fracture criterion εN of the weld nugget are obtained in advance from a micro-tensile test and an FEM analysis simulating it, and are applied to the corresponding parts for fracture judgment. .
As described above, a fracture analysis model is obtained in fracture analysis model creation S12.

The fracture analysis model creation S12 will be described with a more specific example as follows. FIG. 7 shows a diagram for explanation.
In this example, the shape of the entire joint is two steel plates (steel plate 20a, steel plate 20b) having a plate thickness of 1.6 mm, a plate width of 40 mm, and a length of 50 mm. is overlaid with This was modeled in a 1/2 symmetrical shape in the plate width direction to obtain an overall shape 20 .
Next, the analysis mesh data, liquid phase distribution, martensite volume fraction distribution, and thickness direction stress distribution saved in the welding process analysis S11 are read. In this example, the analysis mesh data is two-dimensional axisymmetric, so it is copied up to 180° in the circumferential direction and converted to hexahedral and/or tetrahedral elements, and the stress distribution in the plate thickness direction is also copied up to 180° in the circumferential direction. and the shape 21 in the vicinity of the weld. This was incorporated into the overall shape 20 of the joint divided into meshes by hexahedral elements to form a welded joint shape 22 .

The breaking standard (here, breaking strain considering the effect of stress triaxiality) was set for each element according to the data corresponding to the site. FIG. 8 shows the rupture criteria of the base metal, HAZ, and weld nugget obtained from the micro-tensile test and FEM analysis simulating it in advance. Other material property data such as a deformation resistance curve can be similarly calculated.
A welded joint shape model is created as described above.

Returning to FIG. 2, the fracture prediction calculation S13 will be described. In the fracture prediction calculation S13, using the welded joint shape model obtained in the fracture analysis model creation S12, boundary conditions and load conditions are set, stress analysis is performed, and joint strength and fracture mode are output.
General-purpose numerical analysis software or a self-made numerical analysis program can be used for such stress analysis.

By performing the stress analysis in this way, specifically, for example, the following results can be obtained. FIG. 9 shows analysis conditions. In this example, a symmetrical condition was applied to the central plane 24 in the sheet width direction, the end portion 25 was completely restrained, and a tensile load of 2000 mm/sec was applied to the opposite end portion 26 .
FIG. 10 shows the rupture mode by rupture simulation. FIG. 10 shows how the amount of tension increases from (a) to (c). In each figure of (a) to (c), the left side is an overall view, and the right side is an enlarged view of the welded portion. As can be seen from these figures, it can be seen that fracture occurs in the vicinity of the weld according to the tensile load.

FIG. 11 shows the error in the joint strength of the FEM analysis results in this example with respect to the results of tensile tests conducted under the same conditions using actual materials. The error is within 10%, and it can be seen that the FEM analysis results correspond well with the tensile test results.

As described above, according to the spot weld fracture prediction method S10, the welded joint shape model is created directly from the spot welding process analysis result without referring to the cross-sectional photograph of the experiment, so manual intervention work is reduced. and shorten the construction period. In addition, the shape of the welding nugget, HAZ, and indentation can be modeled in a state close to the actual state, which leads to higher accuracy of fracture prediction. In addition, since the stress distribution in the thickness direction calculated by the welding process calculation is set as the residual stress, the fracture prediction is based on an analysis model that is close to the actual situation, taking into consideration the fracture risk increase due to tensile residual stress and the fracture risk reduction due to compressive residual stress. lead to higher precision.

FIG. 12 is a diagram conceptually showing the configuration of a spot-welded portion fracture prediction calculation device 30 according to one embodiment for performing specific calculations in accordance with the above-described spot-welded portion fracture prediction method S10. The spot weld fracture prediction calculation device 30 has an input means 31 , an arithmetic device 32 , and a display means 38 . The computing device 32 includes computing means 33 , RAM 34 , storage means 35 , receiving means 36 and output means 37 . The input means 31 also includes a keyboard 31a, a mouse 31b, and an external storage device 31c functioning as one of storage media.

The calculation means 33 is constituted by a so-called CPU (Central Operator), and is a means which is connected to each of the constituent members described above and can control them. Also, various programs 35a stored in a storage means 35 functioning as a storage medium are executed, and based on this, data generation for each process of the above-described spot weld fracture prediction method S10 and data from the database 35b are executed. It is also the computing means 33 that performs computation as a means for selecting .

The RAM 34 is a component that functions as a work area for the computing means 33 and as a temporary data storage means. The RAM 34 can be composed of SRAM, DRAM, flash memory, etc., and is similar to known RAM.

The storage unit 35 is a member that functions as a storage medium in which programs and data that serve as the basis for various calculations are stored. Further, the storage means 35 may be capable of storing various intermediate and final results obtained by executing the program. More specifically, the storage means 35 stores (stores) a program 35a, a database 35b, and an intermediate result 35c. Other information may also be stored together.

Here, the stored program 35a includes a simulation program that serves as a basis for calculating each process of the above-described spot welded portion fracture prediction method S10. That is, the simulation program includes a welding process calculation step, a fracture analysis model creation step, and a fracture prediction calculation step so as to correspond to the flow of FIG. The specific calculation contents of this program are as explained in the method S10 for estimating breakage of the spot-welded portion.

The database 35b is a database that stores properties such as physical property values related to steel materials. From this database, the necessary data is provided to the program as requested by the program. Examples of the database include mechanical property data, thermophysical property data, and other material property data as described in the spot weld fracture prediction method S10. Mechanical property data includes, for example, Young's modulus, Poisson's ratio, and deformation resistance curve; thermophysical property data includes, for example, specific heat, thermal conductivity, and coefficient of linear expansion; expansion coefficient, transformation plasticity coefficient, and phase transformation latent heat.

As described in the spot weld fracture prediction method S10, the intermediate result 35c is the weld shape, structure distribution, and stress distribution obtained in the welding process calculation S11, and the analysis result obtained in the fracture prediction calculation S13. is. In addition, information obtained in each step of the spot weld fracture prediction method S10, such as overall shape information and mesh information, can also be stored here as an intermediate result.

The receiving means 36 is a structural member having a function of appropriately taking in information from the outside into the arithmetic device 32, and is connected to the input means 31. As shown in FIG. So-called input ports, input connectors, etc. are also included in this category.

The output means 37 is a structural member having a function of appropriately outputting information to the outside among the obtained results, and a display means 38 such as a monitor and various devices are connected here. So-called output ports, output connectors, etc. are also included in this category.

The input device 31 includes, for example, a keyboard 31a, a mouse 31b, an external storage device 31c, and the like. A known keyboard 31a and mouse 31b can be used, and the description thereof is omitted.
The external storage device 31c is known externally connectable storage means, and also functions as a storage medium. Various necessary programs and data can be stored here without any particular limitation. For example, programs and data similar to those of the storage means 35 described above may be stored here.
A known device can be used as the external storage device 31c. These include, for example, CD-ROMs and CD-ROM drives, DVDs and DVD drives, hard disks, various memories, and the like.

In addition, information may be provided to the computing device via the receiving means 36 by network or communication. Similarly, it may be possible to transmit information to an external device via the output means 37 through a network or communication.

According to such a welded portion fracture prediction calculation device 30, it is possible to perform the spot welded portion fracture prediction method S10 described above efficiently and accurately. A computer, for example, can be used as such a weld fracture prediction calculation device 30 .

1 electrode 2 steel material 3 steel material 10 analysis mesh 11, 12 electrode part mesh 13, 14 steel plate part mesh 15 weld metal part in analysis 16 part with martensite volume fraction of 0.9 or more in analysis 20 whole on model Shape 21 Shape near the weld on the model 22 Weld joint shape on the model 24 Width direction central plane (symmetrical conditioning plane)
25 end (restraint condition applied surface)
26 end (load conditioning surface)
30 weld fracture prediction calculation device 31 input means 32 arithmetic device 33 arithmetic means 35 storage means 38 display means A molten nugget S10 spot weld fracture prediction method S11 welding process calculation S12 fracture analysis model creation S13 fracture prediction calculation

Claims (4)

A method of predicting the fracture of a welded joint by spot welding using numerical analysis using the fracture strain as a fracture criterion considering the influence of the stress triaxiality set in the base metal, the heat affected zone and the weld nugget,
performing calculations to obtain the shape of the weld and the stress distribution in the thickness direction in the weld;
creating a model based on data of the shape of the welded joint including the shape and the stress distribution obtained by the calculation;
A fracture prediction method for welded joints, wherein stress analysis is performed using the model, and joint strength and fracture mode are output as analysis results . Determination of rupture is performed by including a rupture criterion in the model, and the rupture strain considering the effect of the stress triaxiality, which is the rupture criterion, is obtained from a micro-tensile test and the FEM analysis results simulating this. The method for predicting fracture of a welded joint according to claim 1, which is obtained in advance based on. A program that causes an arithmetic unit to predict fracture of a welded joint due to spot welding using, as a fracture criterion, fracture strain that takes into account the influence of stress triaxiality set in the base metal, heat-affected zone, and weld nugget,
to the computing device,
performing calculations to obtain the shape of the weld and the stress distribution in the thickness direction in the weld;
forming a data model of the shape of the welded joint including the shape and the stress distribution obtained from the calculation; and
A fracture prediction program for a welded joint for executing a step of performing a stress analysis using the model and outputting the joint strength and the fracture mode as analysis results . A device that predicts the fracture of a welded joint by spot welding using the fracture strain as a fracture criterion considering the influence of the stress triaxiality set in the base metal, the heat affected zone and the weld nugget,
a storage means in which a program is stored;
computing means for performing computation based on the program;
and a display means for displaying the result calculated by the calculation means,
In the computing means,
Calculation to obtain the shape of the weld and the stress distribution in the thickness direction in the weld;
an operation for creating a model based on data of the shape of the welded joint including the shape and the stress distribution obtained by the operation; and
A fracture prediction device for welded joints, which performs stress analysis using the model and performs calculations for outputting joint strength and fracture mode as analysis results .

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