旋转电弧GMAW焊接热过程数值模拟及焊缝成形质量研究
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摘要
旋转电弧传感器具有抗强磁场、抗弧光和抗高温的独特能力,它与焊接电弧总是统一的整体,可以进行实时焊缝跟踪,因此它具有工业应用的前景。目前对该项技术的研究主要集中在焊缝跟踪上,对焊接热过程及焊缝成形等方面的研究较少。由于旋转电弧焊接的复杂性,其焊接工艺参数颇多,如果仅仅靠焊接试验来选择优化焊接工艺,必将花费较多的人力和物力。因此,利用数值模拟技术以及参数优化技术,研究旋转电弧GMAW(熔化极气体保护电弧焊)热过程的三维瞬态温度场和三维瞬态熔池的动态变化过程,掌握旋转电弧焊接的成形规律和智能优化方法,对于旋转电弧传感器技术的广泛应用,有着重要的学术理论和工程实用的意义。
根据旋转电弧GMAW的特点,以低碳钢Q235-A作为焊接工件,选择三种热源模型,即高斯热源模型、双椭圆热源模型和双椭球热源模型,对这几种热源模型的焊接温度场的分布和熔池形状进行了数值模拟计算,并将焊缝形状尺寸的数值模拟结果与实际焊接的实验结果相对比,结果表明,以高斯热源所模拟计算的焊缝形状尺寸吻合得较好。在此基础上,用高斯热源模型进行数值模拟,研究旋转电弧在焊接热过程中三维瞬态温度场和三维瞬态熔池的变化规律,用数值模拟的方法计算出工件上一些点的热循环曲线和热循环参数,借助于红外线测温仪获得了这些点的实际热循环曲线,通过对比,计算的热循环曲线与实验所得的结果吻合得较好,为焊接冶金的分析和焊接微观质量的控制提供了基础。
在ANSYS软件及其二次开发平台上,运用APDL参数化编程技术,对不同的旋转电弧GMAW焊接工艺参数下的焊接热过程进行了进一步的研究,获得了焊接电流、焊接电压、焊接速度、旋转半径、旋转频率和旋转方向等6个工艺参数对三维瞬态焊接温度场和三维瞬态熔池的形状尺寸的影响规律。为旋转电弧在GMAW中优化工艺参数的选择奠定了理论基础。
为了在实际应用中方便快速地获得优化焊接工艺参数,摆脱在焊接工艺设计中对经验依赖的束缚,采用BP网络建立了预测模型,预测焊接工艺参数与焊缝尺寸的关系。在此基础上采用遗传算法进行寻优,得出最优的焊接工艺参数值,并用实验验证了优化工艺参数的正确性。
使用旋转电弧传感器进行了焊接实验,利用金相显微镜对所焊接的接头进行了宏观和微观的研究,结果表明,旋转电弧传感器所焊接的焊缝余高比正常直线运动焊接的焊缝余高要低,且平滑过渡也较好。旋转电弧的不同焊接工艺参数对焊接接头的微观组织有影响,这与旋转电弧焊接时的热循环曲线有直接的关系。对用旋转电弧传感器焊接的接头进行了力学性能和硬度实验研究,结果表明,用根据本文的优化模型所得的焊接工艺参数焊接的接头符合力学性能的要求,焊缝质量是合格的。
Rotating arc sensor with the unique ability of anti-magnetic field, anti-arc, and resisting high temperature resistant, is always consistent with the welding arc. The rotating arc sensor can be used as real-time seam tracking and has the prospect of industrial application. Current research mainly focuses on the technology of seam tracking, while there are few studies on the welding heat transfer and welding shape of rotating arc sensor. Due to the complexity of the rotating arc welding and lots of welding parameters, it will take high human and material resources if only using welding test to select the optimal welding process parameters. Therefore, it has important theoretical and practical engineering significance to use the numerical simulation and optimization technology to research three-dimensional transient temperature field and three-dimensional dynamic process of transient pool under rotating arc welding GMAW (Gas metal arc welding) thermal process. This technology is important to master rotating arc welding method for weld forming rules and intelligent optimization for the extensive use of rotating arc sensor technology.
According to the characteristics of rotating arc GMAW, three heat source models (Gaussian heat source model, double elliptic heat source model and double ellipsoid heat source model) were used for low carbon steel Q235-A work pieces. The welding temperature distribution and molten pool shapes were analysied by numerical simulation and then the numerical simulation results of weld shape were compared with experimental results of actual welding. The results show that the shape and size of the weld is agreed well with the simulation results by using Gaussian heat source model. Then, Gaussian heat source model was used to study 3D transient temperature distribution and 3D transient pool. The thermal cycle curve and parameters of a few specified points on work pieces were calculated by means of numerical simulation. By comparison, the calculated thermal cycling curve coincides well with experimental results which provided the foundation of analysis on welding metallurgy and the control of welding microstructure.
Based on the ANSYS software and second developing platform, a further research was done with APDL parametric programming technique on welding thermal process of different rotating arc welding parameters GMAW to obtain the influence law on 3D transient temperature field and 3D transient pool caused by processing parameters such as welding current, welding voltage, welding speed, the rotation radius, rotating frequency and rotation direction, which was a theoretical basis in the selection of technological parameters on rotating arc in GMAW.
In order to quickly and easily obtain optimizing welding process parameters and get rid of the bondage of the experience of welding design in practical applications, the BP network was adopted here to construct a forecast model to predict the relationship between welding parameters and weld size. On this basis, the genetic algorithm is used to global optimization and find out the best welding process parameters and then the correctness of the optimization process parameters is verified by experiment.
The rotating arc sensor was used in welding experiments and the welding joint was observed in macroscopic and microscopic observation by microscope. The results showed that the weld reinforcement of rotating arc sensor welding is lower than that of normal linear motion welding and its transition is smoother. Different process parameters of rotating arc welding affect the welding joint microstructure, which directly related to the thermal cycling curve of rotating arc welding. Mechanical properties and hardness experimental research on the welding joint of rotating arc sensor were processed. The results showed that:the welding joint using the parameters got by the optimization model can meet the requirements of the mechanic performance and welding quality is eligible.
根据旋转电弧GMAW的特点,以低碳钢Q235-A作为焊接工件,选择三种热源模型,即高斯热源模型、双椭圆热源模型和双椭球热源模型,对这几种热源模型的焊接温度场的分布和熔池形状进行了数值模拟计算,并将焊缝形状尺寸的数值模拟结果与实际焊接的实验结果相对比,结果表明,以高斯热源所模拟计算的焊缝形状尺寸吻合得较好。在此基础上,用高斯热源模型进行数值模拟,研究旋转电弧在焊接热过程中三维瞬态温度场和三维瞬态熔池的变化规律,用数值模拟的方法计算出工件上一些点的热循环曲线和热循环参数,借助于红外线测温仪获得了这些点的实际热循环曲线,通过对比,计算的热循环曲线与实验所得的结果吻合得较好,为焊接冶金的分析和焊接微观质量的控制提供了基础。
在ANSYS软件及其二次开发平台上,运用APDL参数化编程技术,对不同的旋转电弧GMAW焊接工艺参数下的焊接热过程进行了进一步的研究,获得了焊接电流、焊接电压、焊接速度、旋转半径、旋转频率和旋转方向等6个工艺参数对三维瞬态焊接温度场和三维瞬态熔池的形状尺寸的影响规律。为旋转电弧在GMAW中优化工艺参数的选择奠定了理论基础。
为了在实际应用中方便快速地获得优化焊接工艺参数,摆脱在焊接工艺设计中对经验依赖的束缚,采用BP网络建立了预测模型,预测焊接工艺参数与焊缝尺寸的关系。在此基础上采用遗传算法进行寻优,得出最优的焊接工艺参数值,并用实验验证了优化工艺参数的正确性。
使用旋转电弧传感器进行了焊接实验,利用金相显微镜对所焊接的接头进行了宏观和微观的研究,结果表明,旋转电弧传感器所焊接的焊缝余高比正常直线运动焊接的焊缝余高要低,且平滑过渡也较好。旋转电弧的不同焊接工艺参数对焊接接头的微观组织有影响,这与旋转电弧焊接时的热循环曲线有直接的关系。对用旋转电弧传感器焊接的接头进行了力学性能和硬度实验研究,结果表明,用根据本文的优化模型所得的焊接工艺参数焊接的接头符合力学性能的要求,焊缝质量是合格的。
Rotating arc sensor with the unique ability of anti-magnetic field, anti-arc, and resisting high temperature resistant, is always consistent with the welding arc. The rotating arc sensor can be used as real-time seam tracking and has the prospect of industrial application. Current research mainly focuses on the technology of seam tracking, while there are few studies on the welding heat transfer and welding shape of rotating arc sensor. Due to the complexity of the rotating arc welding and lots of welding parameters, it will take high human and material resources if only using welding test to select the optimal welding process parameters. Therefore, it has important theoretical and practical engineering significance to use the numerical simulation and optimization technology to research three-dimensional transient temperature field and three-dimensional dynamic process of transient pool under rotating arc welding GMAW (Gas metal arc welding) thermal process. This technology is important to master rotating arc welding method for weld forming rules and intelligent optimization for the extensive use of rotating arc sensor technology.
According to the characteristics of rotating arc GMAW, three heat source models (Gaussian heat source model, double elliptic heat source model and double ellipsoid heat source model) were used for low carbon steel Q235-A work pieces. The welding temperature distribution and molten pool shapes were analysied by numerical simulation and then the numerical simulation results of weld shape were compared with experimental results of actual welding. The results show that the shape and size of the weld is agreed well with the simulation results by using Gaussian heat source model. Then, Gaussian heat source model was used to study 3D transient temperature distribution and 3D transient pool. The thermal cycle curve and parameters of a few specified points on work pieces were calculated by means of numerical simulation. By comparison, the calculated thermal cycling curve coincides well with experimental results which provided the foundation of analysis on welding metallurgy and the control of welding microstructure.
Based on the ANSYS software and second developing platform, a further research was done with APDL parametric programming technique on welding thermal process of different rotating arc welding parameters GMAW to obtain the influence law on 3D transient temperature field and 3D transient pool caused by processing parameters such as welding current, welding voltage, welding speed, the rotation radius, rotating frequency and rotation direction, which was a theoretical basis in the selection of technological parameters on rotating arc in GMAW.
In order to quickly and easily obtain optimizing welding process parameters and get rid of the bondage of the experience of welding design in practical applications, the BP network was adopted here to construct a forecast model to predict the relationship between welding parameters and weld size. On this basis, the genetic algorithm is used to global optimization and find out the best welding process parameters and then the correctness of the optimization process parameters is verified by experiment.
The rotating arc sensor was used in welding experiments and the welding joint was observed in macroscopic and microscopic observation by microscope. The results showed that the weld reinforcement of rotating arc sensor welding is lower than that of normal linear motion welding and its transition is smoother. Different process parameters of rotating arc welding affect the welding joint microstructure, which directly related to the thermal cycling curve of rotating arc welding. Mechanical properties and hardness experimental research on the welding joint of rotating arc sensor were processed. The results showed that:the welding joint using the parameters got by the optimization model can meet the requirements of the mechanic performance and welding quality is eligible.
引文
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