Markus Wagner, Fabian Günther, Rishabh Rajesh Rao, Uwe Stamm, Dirk Dittrich, Axel Jahn
{"title":"通过战略性地使用仿真方法,为高负载传输部件的激光焊接提供了新的可能性","authors":"Markus Wagner, Fabian Günther, Rishabh Rajesh Rao, Uwe Stamm, Dirk Dittrich, Axel Jahn","doi":"10.2351/7.0001189","DOIUrl":null,"url":null,"abstract":"Laser welding in transmission manufacturing opens up completely new kinds of product solutions with excellent properties in terms of wear, corrosion resistance, and service life. Current welding designs are characterized in particular by difficult-to-weld material combinations (e.g., steel versus cast iron) and a high component stiffness, which is correlated with high residual welding stresses. The major challenge for these mass-produced components remains both their crack-free weldability and their complex cyclic load capacity [U. Stamm, “Rissfreies Laserstrahlschweißen von Mischverbindungen aus Gusseisen und Einsatzstahl, Jahresbericht Fraunhofer IWS 2006” (2006); X. Shu, “Untersuchungen zum Laserstrahlschweißen von Werkstoffkombinationen aus Gußeisen und Stahl,” Dissertation, Shaker, Band 4/94 (1994), ISBN: 3-8265-0098-9; G. Göbel, “Erweiterung der Prozessgrenzen beim Laserstrahlschweißen heißrissgefährdeter Werkstoffe,” Dissertation, Fraunhofer-IRB-Verlag (2007), ISBN: 978-3-8167-7671-0]. Therefore, this contribution presents practical solutions for weld-compatible joint constructions and the reduction of residual stresses on the basis of a representative transmission design. Specifically, a systematic study is being conducted to understand and qualitatively evaluate effective methods for reducing residual weld stresses in circumferential welds. The recommendations developed as part of this study take particular account of the influence of process modifications, material conditions, and geometric aspects on weldability and component distortion. Here, structural welding simulations are performed and verified by experimental welding trials, including metallographic examinations. To ensure the required component fatigue strength, a practical concept for determining Wöhler curves is presented, which is based on structural mechanical simulations and multiaxial fatigue strength tests on simplified test specimens. The adaptations developed in this way facilitate the production of difficult-to-weld and highly stressed transmission components. In particular, time-consuming and cost-intensive iterations of laser welding tests can be significantly reduced or even eliminated [Brenner et al., “Neuere Ergebnisse zum Schweißen von Eisenbasiswerkstoffen mit Faserlasern, 5. Laser-Anwenderforum,” Strahltechnik Band 28 (2006), pp. 139–148, ISBN: 3-933762-18-9, S]. Furthermore, the systematic investigations provide effective recommendations for phenomenological understanding and solving typical welding challenges in practice [J. Standfuß, “Ganzheitliche innovative fügetechnische Konzepte am Beispiel des PKW-Antriebsstranges,” Fraunhofer Verlag (2010), ISBN: 978-3-8396-0125-9]. This applies, in particular, to load-transmitting components in the fields of e-mobility, aerospace, and industrial engineering [Wagner et al., “Entwickeln und Auslegen von lasergeschweißten Getriebe-komponenten für die Luftfahrt,” DVS-Berichte Band 365 (2020), pp. 62–69, ISBN: 978-3-96144-098-6].","PeriodicalId":50168,"journal":{"name":"Journal of Laser Applications","volume":null,"pages":null},"PeriodicalIF":1.7000,"publicationDate":"2023-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":"{\"title\":\"New possibilities for laser welding of highly loaded transmission components by strategic use of simulation methods\",\"authors\":\"Markus Wagner, Fabian Günther, Rishabh Rajesh Rao, Uwe Stamm, Dirk Dittrich, Axel Jahn\",\"doi\":\"10.2351/7.0001189\",\"DOIUrl\":null,\"url\":null,\"abstract\":\"Laser welding in transmission manufacturing opens up completely new kinds of product solutions with excellent properties in terms of wear, corrosion resistance, and service life. Current welding designs are characterized in particular by difficult-to-weld material combinations (e.g., steel versus cast iron) and a high component stiffness, which is correlated with high residual welding stresses. The major challenge for these mass-produced components remains both their crack-free weldability and their complex cyclic load capacity [U. Stamm, “Rissfreies Laserstrahlschweißen von Mischverbindungen aus Gusseisen und Einsatzstahl, Jahresbericht Fraunhofer IWS 2006” (2006); X. Shu, “Untersuchungen zum Laserstrahlschweißen von Werkstoffkombinationen aus Gußeisen und Stahl,” Dissertation, Shaker, Band 4/94 (1994), ISBN: 3-8265-0098-9; G. Göbel, “Erweiterung der Prozessgrenzen beim Laserstrahlschweißen heißrissgefährdeter Werkstoffe,” Dissertation, Fraunhofer-IRB-Verlag (2007), ISBN: 978-3-8167-7671-0]. Therefore, this contribution presents practical solutions for weld-compatible joint constructions and the reduction of residual stresses on the basis of a representative transmission design. Specifically, a systematic study is being conducted to understand and qualitatively evaluate effective methods for reducing residual weld stresses in circumferential welds. The recommendations developed as part of this study take particular account of the influence of process modifications, material conditions, and geometric aspects on weldability and component distortion. Here, structural welding simulations are performed and verified by experimental welding trials, including metallographic examinations. To ensure the required component fatigue strength, a practical concept for determining Wöhler curves is presented, which is based on structural mechanical simulations and multiaxial fatigue strength tests on simplified test specimens. The adaptations developed in this way facilitate the production of difficult-to-weld and highly stressed transmission components. In particular, time-consuming and cost-intensive iterations of laser welding tests can be significantly reduced or even eliminated [Brenner et al., “Neuere Ergebnisse zum Schweißen von Eisenbasiswerkstoffen mit Faserlasern, 5. Laser-Anwenderforum,” Strahltechnik Band 28 (2006), pp. 139–148, ISBN: 3-933762-18-9, S]. Furthermore, the systematic investigations provide effective recommendations for phenomenological understanding and solving typical welding challenges in practice [J. Standfuß, “Ganzheitliche innovative fügetechnische Konzepte am Beispiel des PKW-Antriebsstranges,” Fraunhofer Verlag (2010), ISBN: 978-3-8396-0125-9]. This applies, in particular, to load-transmitting components in the fields of e-mobility, aerospace, and industrial engineering [Wagner et al., “Entwickeln und Auslegen von lasergeschweißten Getriebe-komponenten für die Luftfahrt,” DVS-Berichte Band 365 (2020), pp. 62–69, ISBN: 978-3-96144-098-6].\",\"PeriodicalId\":50168,\"journal\":{\"name\":\"Journal of Laser Applications\",\"volume\":null,\"pages\":null},\"PeriodicalIF\":1.7000,\"publicationDate\":\"2023-11-01\",\"publicationTypes\":\"Journal Article\",\"fieldsOfStudy\":null,\"isOpenAccess\":false,\"openAccessPdf\":\"\",\"citationCount\":\"0\",\"resultStr\":null,\"platform\":\"Semanticscholar\",\"paperid\":null,\"PeriodicalName\":\"Journal of Laser Applications\",\"FirstCategoryId\":\"1085\",\"ListUrlMain\":\"https://doi.org/10.2351/7.0001189\",\"RegionNum\":4,\"RegionCategory\":\"工程技术\",\"ArticlePicture\":[],\"TitleCN\":null,\"AbstractTextCN\":null,\"PMCID\":null,\"EPubDate\":\"\",\"PubModel\":\"\",\"JCR\":\"Q3\",\"JCRName\":\"MATERIALS SCIENCE, MULTIDISCIPLINARY\",\"Score\":null,\"Total\":0}","platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Laser Applications","FirstCategoryId":"1085","ListUrlMain":"https://doi.org/10.2351/7.0001189","RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"MATERIALS SCIENCE, MULTIDISCIPLINARY","Score":null,"Total":0}
引用次数: 0
摘要
激光焊接在传动制造中开辟了全新的产品解决方案,在耐磨、耐腐蚀和使用寿命方面具有优异的性能。当前的焊接设计尤其以难以焊接的材料组合(例如,钢与铸铁)和高部件刚度为特征,这与高残余焊接应力相关。这些量产部件面临的主要挑战是其无裂纹焊接性和复杂的循环载荷能力。斯塔姆,“激光辐射与激光辐射”,德国劳恩霍夫学会(2006);舒欣,“Untersuchungen zum Laserstrahlschweißen von Werkstoffkombinationen aus Gußeisen und Stahl”,博士论文,振动,第4/94期(1994),ISBN: 3-8265-0098-9;G. Göbel,“Erweiterung der Prozessgrenzen beim Laserstrahlschweißen heißrissgefährdeter Werkstoffe”,Dissertation, Fraunhofer-IRB-Verlag (2007), ISBN: 978-3-8167-7671-0]。因此,这一贡献为焊接兼容接头结构和减少残余应力提供了实用的解决方案,并以代表性传动设计为基础。具体来说,正在进行一项系统的研究,以了解和定性评估减少环向焊缝残余应力的有效方法。作为本研究的一部分,提出的建议特别考虑了工艺修改、材料条件和几何方面对可焊性和部件变形的影响。在这里,进行了结构焊接模拟,并通过实验焊接试验进行了验证,包括金相检查。为了保证构件所需的疲劳强度,提出了一种基于结构力学模拟和简化试件多轴疲劳强度试验的Wöhler曲线确定的实用概念。以这种方式开发的适应性有助于生产难以焊接和高应力的传动部件。特别是,激光焊接测试的耗时和成本密集的迭代可以大大减少甚至消除[Brenner等人,“Neuere Ergebnisse zum schweien von Eisenbasiswerkstoffen mit faserlasen, 5]。Laser-Anwenderforum, " Strahltechnik Band 28 (2006), pp. 139-148, ISBN: 3-933762-18-9, S]。此外,系统的研究为理解现象学和解决实践中的典型焊接挑战提供了有效的建议[J]。斯坦弗斯,“Ganzheitliche innovative f getechnische Konzepte am Beispiel des PKW-Antriebsstranges”,弗劳恩霍夫出版社(2010),ISBN: 978-3-8396-0125-9。这尤其适用于电动汽车、航空航天和工业工程领域的负载传输组件[Wagner等人,“Entwickeln und Auslegen von lasergeschweißten Getriebe-komponenten f r die Luftfahrt,”DVS-Berichte Band 365 (2020), pp. 62-69, ISBN: 978-3-96144-098-6]。
New possibilities for laser welding of highly loaded transmission components by strategic use of simulation methods
Laser welding in transmission manufacturing opens up completely new kinds of product solutions with excellent properties in terms of wear, corrosion resistance, and service life. Current welding designs are characterized in particular by difficult-to-weld material combinations (e.g., steel versus cast iron) and a high component stiffness, which is correlated with high residual welding stresses. The major challenge for these mass-produced components remains both their crack-free weldability and their complex cyclic load capacity [U. Stamm, “Rissfreies Laserstrahlschweißen von Mischverbindungen aus Gusseisen und Einsatzstahl, Jahresbericht Fraunhofer IWS 2006” (2006); X. Shu, “Untersuchungen zum Laserstrahlschweißen von Werkstoffkombinationen aus Gußeisen und Stahl,” Dissertation, Shaker, Band 4/94 (1994), ISBN: 3-8265-0098-9; G. Göbel, “Erweiterung der Prozessgrenzen beim Laserstrahlschweißen heißrissgefährdeter Werkstoffe,” Dissertation, Fraunhofer-IRB-Verlag (2007), ISBN: 978-3-8167-7671-0]. Therefore, this contribution presents practical solutions for weld-compatible joint constructions and the reduction of residual stresses on the basis of a representative transmission design. Specifically, a systematic study is being conducted to understand and qualitatively evaluate effective methods for reducing residual weld stresses in circumferential welds. The recommendations developed as part of this study take particular account of the influence of process modifications, material conditions, and geometric aspects on weldability and component distortion. Here, structural welding simulations are performed and verified by experimental welding trials, including metallographic examinations. To ensure the required component fatigue strength, a practical concept for determining Wöhler curves is presented, which is based on structural mechanical simulations and multiaxial fatigue strength tests on simplified test specimens. The adaptations developed in this way facilitate the production of difficult-to-weld and highly stressed transmission components. In particular, time-consuming and cost-intensive iterations of laser welding tests can be significantly reduced or even eliminated [Brenner et al., “Neuere Ergebnisse zum Schweißen von Eisenbasiswerkstoffen mit Faserlasern, 5. Laser-Anwenderforum,” Strahltechnik Band 28 (2006), pp. 139–148, ISBN: 3-933762-18-9, S]. Furthermore, the systematic investigations provide effective recommendations for phenomenological understanding and solving typical welding challenges in practice [J. Standfuß, “Ganzheitliche innovative fügetechnische Konzepte am Beispiel des PKW-Antriebsstranges,” Fraunhofer Verlag (2010), ISBN: 978-3-8396-0125-9]. This applies, in particular, to load-transmitting components in the fields of e-mobility, aerospace, and industrial engineering [Wagner et al., “Entwickeln und Auslegen von lasergeschweißten Getriebe-komponenten für die Luftfahrt,” DVS-Berichte Band 365 (2020), pp. 62–69, ISBN: 978-3-96144-098-6].
期刊介绍:
The Journal of Laser Applications (JLA) is the scientific platform of the Laser Institute of America (LIA) and is published in cooperation with AIP Publishing. The high-quality articles cover a broad range from fundamental and applied research and development to industrial applications. Therefore, JLA is a reflection of the state-of-R&D in photonic production, sensing and measurement as well as Laser safety.
The following international and well known first-class scientists serve as allocated Editors in 9 new categories:
High Precision Materials Processing with Ultrafast Lasers
Laser Additive Manufacturing
High Power Materials Processing with High Brightness Lasers
Emerging Applications of Laser Technologies in High-performance/Multi-function Materials and Structures
Surface Modification
Lasers in Nanomanufacturing / Nanophotonics & Thin Film Technology
Spectroscopy / Imaging / Diagnostics / Measurements
Laser Systems and Markets
Medical Applications & Safety
Thermal Transportation
Nanomaterials and Nanoprocessing
Laser applications in Microelectronics.