高速列车铝合金车身双热源搅拌摩擦焊仿真

Numerical simulation of friction stir welding for aluminum alloy railway carriage manufacturing

高速列车采用超长铝合金型材作为车身新材料。搅拌摩擦焊以固相连接原理成为高铁车身制造新工艺。针对单热源模型不足,考虑搅拌轴肩转动摩擦生热和搅拌头塑变剪切生热,建立搅拌摩擦焊双热源有限元模型。基于传统熔焊方式,实现满足搅拌焊特征的双面挤压型材接头变形设计。通过ANSYS二次开发,完成该工艺移动瞬态热交换数值仿真,获得焊接全程三维温度场分布,仿真结果与试验数据吻合良好。结果表明,该仿真模型可行,仿真结果合理,为高铁车身国产化制造工艺吸收和工艺优化提供参考。

High speed railway(HSR) uses aluminum hollow extrusions as new material and friction stir welding(FSW) is an innovative solid phase welding for such carriage manufacturing.Considering both the heat generation from tool shoulder friction and plastic deformation near the tool pin,a dual source finite element model of FSW is presented and a variety of weld joint designs are realized which satisfy the feature of FSW for the double skinned extrusion aluminum alloy structure.By ANSYS-APDL based re-exploitation,moving heat sources simulation is realized,and temperature field is obtained during the welding.The calculated results are in good agreernent with experimental data,which indicate the model's feasibility and accuracy.It will benefit the digestion & assimilation of domestic-made level HSR vehicle manufacturing technology and provide reference for FSW process parameters optimization.