采用石墨和铜钨电极实现电触头电阻钎焊的仿真研究与能耗比较

Simulation and Energy Consumption Comparison of Contact Resistance Brazing by Using Graphite and Copper Tungsten Electrode

提出了导电、传热耦合作用的有限元模型,数值分析了石墨电极和铜钨电极对电触头电阻钎焊能耗、焊接时间的不同影响。结果表明,采用铜钨电极的焊接时间不超过石墨的1/3,且电阻钎焊的焊接时间均随焊接电流的增加而减小;采用铜钨电极焊接的能耗比石墨小一个数量级,且能耗均随焊接电流的变大而减小,所花电费降为石墨的43.8%,所焊电触头数是石墨的2.3倍。相对于石墨而言,选用铜钨电极可大幅节省电触头电阻钎焊的生产成本,并提高生产效率。仿真结果和试验吻合良好,证明了有限元方法仿真分析电阻钎焊过程的可行性。

This paper proposed a finite element model on conductive and heat transfer coupling, and analyzed mumerically the influence of graphite and copper tungsten electrode on contact resistance brazing＇ s consumption and welding time. The results show that the welding time by using copper tungsten electrode is 1/3 as long as that by graphite, and all the welding time is reduced when the welding current increases. The consumption by using copper tungsten is less than that by graphite by one order of magnitude, and all the consumption is reduced when the welding current increases. The electricity cost is 43.8% of that by graphite,and the welded contacts are 2.3 times as more as that by graphite. Relative to graphite, using copper tungsten electrode cam greatly save the production cost of contact resistance brazing and inhanee the efficiency. The simulation results agree well with the test results, which proves the feasibility of the method.