脉冲参数对脉冲DE-GMAW熔滴过渡影响的建模及仿真

Modeling and Simulation of the Effect of Pulse Parameters for Metal Transfer in Pulsed DE-GMAW

针对铝-钢等现有焊接方法效率低、成本高等缺点,提出了一种低成本、热输入精确可控的脉冲旁路耦合电弧MIG焊(DE-GMAW)焊接方法.建立了脉冲旁路耦合电弧MIG焊数学模型,从焊丝熔化模型和电磁不稳定收缩模型仿真研究脉冲参数对熔滴过渡的影响规律.结果表明:在脉冲旁路耦合电弧MIG焊过程中,在主路平均电流和旁路平均电流不变的情况下,随着主路或旁路峰值电流的增大、脉冲占空比的变大,熔滴过渡频率会变大,更有利于脉冲旁路耦合电弧MIG焊熔滴的过渡,而且峰值电流对熔滴过渡的影响力要大于脉冲占空比.

Aiming at the problems of existing welding methods for joining aluminum to steel,low efficiency,high cost,a new high efficiency and low heat input method was proposed.In order to study the effect of pulsed parameters for metal transfer,a mathematics model for Pulsed DE-GMAW was built and the influence of pulsed parameters was analyzed by wire melting model and pinch instability theory model.The result show that the peak current and duty ratio can be increased to improve the metal transfer frequency in the case of maintaining the same total current.The influence of peak current is greates than duty ratio for metal transfer.