商用车桥壳直缝深熔弧焊接数值模拟及试验研究

Numerical Simulation and Experimental Study of D-Arc Deep Penetration Welding in Straight Seam of Commercial Vehicle Axle Housing

应用D-Arc深熔焊接工艺对商用车12 mm厚的桥壳直缝进行无坡口焊接试验,并对焊接后的桥壳进行焊缝剖面、焊接热循环以及残余应力的测量分析;基于Simufact Welding软件,结合焊接接头的剖面形态,建立桥壳直缝焊接有限元分析模型,采用高斯面热源+圆锥体热源的复合热源模型来模拟D-Arc深熔焊接过程中热量输入的表现,对桥壳直缝D-Arc深熔焊接过程进行了数值模拟,得到桥壳在不同时刻的温度及应力分布状态,模拟计算结果与试验结果基本吻合,验证了该有限元分析模型的可靠性,同时也证明了D-Arc深熔焊接工艺在商用车桥壳焊接场景的应用可行性。

The D-Arc deep penetration welding process was applied to the straight joint welding test of 12 mm-thick axle housing of commercial vehicles,and the weld profile,welding thermal cycle and residual stress were measured and analyzed.Based on Simufact Welding software and combined with the profile shape of the welded joint,a finite element analysis model for straight seam welding of the axle housing was established.A composite heat source model of Gaussian surface heat source and cone heat source was adopted to simulate the heat input in the D-Arc deep penetration welding process,and the process of straight seam D-Arc deep penetration welding was numerically simulated.The temperature and stress distribution of the axle housing at different times were obtained,and the simulation results were basically consistent with the test results,which verified the reliability of the finite element analysis model,and also proved the feasibility of D-Arc deep penetration welding process in the welding scene of commercial vehicle axle housing.