基于温度场仿真的塑料感应焊接工艺参数优化

Optimization of Plastic Induction Welding Parameters Based on Temperature Field Simulation

特种热塑性工程塑料的应用对高端制造领域的轻量化、高性能化和环保化起着极其重要的作用。为了研究塑料与金属的感应焊接过程,更好地理解该过程中不同工艺参数对焊接金属表面温度的影响,并探索最适合的塑料感应焊接工艺参数,利用有限元仿真软件ANSYS Maxwell进行电磁场模拟,采用中心复合设计方法完成塑料感应焊接工艺参数方案设计,再通过该有限元仿真软件求解出相应的金属表面温度。基于多元非线性理论,建立了电流强度、电流频率、焊接间隙与金属表面平均温度之间的多元非线性回归模型。采用逐步回归的迭代策略,分析了各工艺参数以及各工艺参数交互作用对金属表面平均温度的影响程度。结果表明:二次拟合模型具有最佳的拟合度,决定系数R^(2)=0.956;电流强度是对金属表面平均温度影响最大的主效应,电流强度与焊接间隙的交互作用是影响金属表面平均温度的主要交互效应;基于该二次拟合模型,在该有限元仿真软件上进行了工艺参数优化并预测了多组最佳工艺参数组合,其仿真试验结果与回归分析结果误差在7%以内,说明该二次拟合模型预测结果准确可靠。相关理论和方法可为塑料在汽车、船舶、航空、航天等高端制造领域的应用提供参考。

The application of special thermoplastic engineering plastics promotes high-end manufacturing advancing towards light weight,high-performance,and environmental protection.To study the induction welding process between plastics and metals,better understand the influence of different parameters on the surface temperature of welded metals,and explore the most suitable parameters for plastic induction welding,the finite element analysis software ANSYS Maxwell was adopted for electromagnetic field simulation,the central composite design method was employed to design the parameters for plastic induction welding,then the temperature of the corresponding metal surface was solved through the finite element analysis software.Based on the multivariate nonlinear theory,an iterative strategy of stepwise regression was adopted in the multivariate nonlinear regression model to analyze the impact of current intensity,current frequency,welding gap and their interactions on the average temperature of the metal surface.The results indicated that the quadratic model had the best fit with a determination coefficient of R^(2)=0.956.The current intensity was the principal effect that had the greatest impact on the average temperature of the metal surface.The interaction between the current intensity and welding gap was the main interactive effect that affected the average temperature of the metal surface.Based on the quadratic model,multiple optimal parameter combinations were predicted and then verified through the finite element analysis software.The deviation between the simulation experiment results and regression analysis results was within 7%,indicating a high accuracy and reliability of the quadratic model.The theories and methods related to this study provided a solid reference for the application of plastics in manufacturing fields such as automobiles,ships,aviation,and aerospace.