等离子焊接气体保护效果数值模拟研究
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摘要
等离子焊接焊缝深宽比大,能直接穿透被焊工件,实现单面焊双面成形,焊接质量好,在造船、航空航天等众多领域有着广泛的应用。焊枪是等离子焊接的关键技术,是保证焊接质量的基础,但是国内等离子焊枪的设计依然停留在模仿或经验设计的阶段,科学性不高,用此方法设计的焊枪技术含量低,稳定性较差,高质量的焊枪依然需要进口。本文针对苏州华焊科技有限公司提供的不同结构的等离子焊枪,采用数值模拟的方法模拟了焊枪喷嘴的气体保护效果,模拟了保护气与离子气流量及比例、喷嘴与工件之间的距离、保护气罩位置、焊枪喷嘴的结构等参数对保护效果的影响,得出了各个参数变化时流场状态的变化规律。模拟结果可为等离子焊接气体保护参数制定及其焊枪的设计提供理论指导。计算机模拟辅助焊枪结构设计(Computer Simulation Assist the Design of Welding Torch)的方法还可以适用于等离子喷涂、钨极氩弧焊、熔化极气体保护焊等一切气体保护加工方法的枪体结构设计。
Plasma arc welding has the character of high depth-to-width ratio and good welding quality, the workpiece can be penetrated directly by this way. This method can achieve the result of one-side welding with back formation. So, this method has wide applications in many areas such as shipbuilding and aerospace industry. Welding torch is the key technology of plasma arc welding, it’s the basis of achieving perfect welding quality. The design of plasma arc welding torch still stays in the imitation or empirical stage in our country, this method is not scientific enough. The torch designed by this method is low-skilled, and the high quality welding torch still needs to be imported. On the basis of the plasma arc welding torch provided by Suzhou Ahand Ltd, the shielding gas protective effect of the nozzle of the torch was simulated by the method of numerical simulation. The influence of flux of shielding gas, the ratio of plasma gas and shielding gas, distance between the nozzle of torch and workpiece, position of shielding gas cup and structure of the nozzle on the flow field was simulated. The changing regularity of the state of flow field with the change of these parameters was summarized. The simulation result provided some theoretical basis for the formulation of technological parameters and the design of welding torch. The method of“Computer Simulation Assist the Design of Welding Torch”can also be used for the torch design of plasma spray, gas tungsten arc welding and gas metal arc welding et al.
Plasma arc welding has the character of high depth-to-width ratio and good welding quality, the workpiece can be penetrated directly by this way. This method can achieve the result of one-side welding with back formation. So, this method has wide applications in many areas such as shipbuilding and aerospace industry. Welding torch is the key technology of plasma arc welding, it’s the basis of achieving perfect welding quality. The design of plasma arc welding torch still stays in the imitation or empirical stage in our country, this method is not scientific enough. The torch designed by this method is low-skilled, and the high quality welding torch still needs to be imported. On the basis of the plasma arc welding torch provided by Suzhou Ahand Ltd, the shielding gas protective effect of the nozzle of the torch was simulated by the method of numerical simulation. The influence of flux of shielding gas, the ratio of plasma gas and shielding gas, distance between the nozzle of torch and workpiece, position of shielding gas cup and structure of the nozzle on the flow field was simulated. The changing regularity of the state of flow field with the change of these parameters was summarized. The simulation result provided some theoretical basis for the formulation of technological parameters and the design of welding torch. The method of“Computer Simulation Assist the Design of Welding Torch”can also be used for the torch design of plasma spray, gas tungsten arc welding and gas metal arc welding et al.
引文
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[13] J. J. Gonzalez, P. Freton, A. Gleizes. Comparisons between two- and three-dimensional models: gas injection and arc attachment [J]. Journal of Physics D: Applied Physics, 2002, 35(24): 3181-3191.
[14]殷凤良,胡绳荪,高忠林,等.等离子弧焊中电弧反翘现象的数值模拟[J].焊接学报,2007,28(9):29-32.
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[16] Y. F. Hsu, B. Rubinsky. Two-dimensional heat transfer study on the keyhole plasma arc welding process [J]. International Journal of Heat and Mass Transfer, 1988, 31(7):1409-1421.
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[18]董洪刚,高洪明,吴林.固定电弧等离子弧焊接热传导的数值计算[J].焊接学报,2002,23(4):24-26.
[19] R. G. Keanini, B. Rubinsky. Three-dimensional simulation of the plasma arc welding process [J]. International Journal of Heat and Mass Transfer, 1993, 36(13):3283-3298.
[20]孙俊生,武传松,董博玲.PAW+TIG电弧双面焊接小孔形成过程的数值模拟[J].金属学报,2003,39(1):79-84.
[21]孙俊生,武传松.等离子与钨极双面电弧焊接热过程的数值模拟[J].金属学报,2003,39(5):499-504.
[22]武传松,王怀刚,张明贤.小孔等离子弧焊接热场瞬时演变过程的数值分析[J].金属学报,2006,42(3):311-316.
[23]刘望兰,胡绳荪,马立.三维静态锥体热源穿孔等离子弧焊接熔池的数值模拟[J].焊接学报,2006,27(6):33-36.
[24]李力,胡绳荪,殷凤良,等.等离子弧焊接熔池温度场的三维数值模拟[J].天津大学学报,2007,40(10):1260-1264.
[25]王小杰,武传松,陈茂爱.等离子弧定点焊熔池穿孔过程的数值分析[J].金属学报,2010,46(8):984-990.
[26] D. Rosenthal. Mathematical theory of heat distribution during welding and Cutting [J]. Welding Journal. 1941, 20(5):220—234.
[27]张文钺.焊接传热学[M].北京:机械工业出版社,1989.
[28]莫立春,钱百年,国旭明,等.焊接热源计算模式的研究进展[J].焊接学报,2001,22(3):93-96.
[29] T. W. Eager and N. S. Tsai. Temperature fields produced by traveling distributed heat sources[J]. Welding Journal, 1983, 62(12): 3462s-3552s.
[30] J. Goldak. A new finite model for welding heat source[J]. Metallurgical. Transactions B,1984,15B(2):299-305.
[31]吴甦,赵海燕,王煜,等.高能束焊接数字模拟中的新型热源模型[J].焊接学报,2004,25(1):91-94.
[32] C. S. Wu, H. G. Wang, Y. M. Zhang. A new heat source model for keyhole plasma arc welding in FEM analysis of the temperature profile [J]. Welding Journal, 2006, 85(12):284s-291s.
[33]张义顺,董晓强,李德元.等离子枪体内部流场及温升的模拟分析[J].焊接学报,2005,26(9):77-80.
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