Nd:YAG激光烧蚀裂解加工技术模拟分析与实验研究

Finite element analysis and experimental studies on fracture splitting processing by Nd:YAG laser ablation

激光裂解技术能够极大改善发动机缸体主轴承座的加工质量并显著提高加工效率.为探寻Nd:YAG激光烧蚀球墨铸铁材料裂解槽的裂解性能,本文基于有限元法成功构建了发动机缸体主轴承座激光裂解加工过程仿真模型,针对QT500-7球墨铸铁主轴承座的裂解参数进行了仿真分析.研究结果表明:在影响裂解质量的三个裂解槽几何参数中,槽深较张角及曲率半径对裂解载荷的影响效应更为明显;裂解载荷随槽深的增加而迅速降低,随槽张角和曲率半径的增加而升高;QT500-7球墨铸铁发动机缸体主轴承座激光裂解加工优化参数应为裂解槽深选为0.5 mm,裂解槽张角选为60°,裂解槽半径选为0.2 mm.有限元模拟分析结果得到了单向拉伸实验结果的验证.本工作通过ABAQUS仿真模拟及大量裂解载荷试验确立了裂解槽几何形状的优化参数,为显著降低裂解载荷和优化裂解工艺提供了数值参考,有利于实现发动机缸体加工的快速发展,从而促进汽车工业实现绿色制造.

Laser fracture splitting technology significantly improves the processing quality and efficiency of engine crankcase main bearing block.In order to research the splitting mechanism of ductile iron material fracture notch cauterized by Nd：YAG Laser,the FEAmodel of fracture splitting processing of engine crankcase main bearing block has been developed successfully.The splitting parameters of ductile iron material（QT500-7） main bearing block is analyzed.The numerical simulation results indicate that：among all the key parameters affecting the quality of fracture splitting,the effect of notch depth on fracture splitting load is more obvious than that of the notch opening angle and radius.The value of splitting load decreases rapidly with the increasing notch depth,while the splitting load increases with the increasing notch angle and radius.The optimum value of the notch depth,angle,and radius should be respectively at 0.5 mm,60°,and 0.2 mm.The results have been proved by experiments.The optimum parameters obtained from the ABAQUS simulation and experiments provide a numerical reference for significantly reducing the splitting load and optimizing the fracture splitting process,help to achieve the rapid development of engine block process and promote the green manufacture of automobile industry.