对 FSW 过程中的材料流动和缺陷形成进行数值模拟,以预测焊接故障位置

IF 1.9 3区 工程技术 Q3 ENGINEERING, MANUFACTURING
A. Choudhary, Rahul Jain
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引用次数: 0

摘要

预测焊接试样的失效位置对各种工业应用都很重要。在搅拌摩擦焊中,材料流动和最终缺陷都会对失效位置产生影响。在当前的研究中,开发了一种三维耦合欧拉格拉格朗日(CEL)来研究材料流动并预测厚度为 3 毫米的 AA2024 在搅拌摩擦焊接过程中产生的缺陷。为了尽量减少缺陷并获得良好的焊接质量,使用了方形销钉。所开发的模型通过实验观察到的轴向力和主轴扭矩进行了验证。数值预测的缺陷与实验断裂位置和强度进行了验证,以检验模型在量化缺陷方面的稳健性。当转速从 600 rpm 提高到 1500 rpm 时,峰值温度上升了 10.7%。此外,当焊接速度从 60 mm/min 提高到 150 mm/min 时,峰值温度上升了 6.1%。转速和焊接速度越高,缺陷越少。在 1500 rpm 和 150 mm/min 的工艺条件下,焊接强度最高,达到 447 MPa。对不同的工艺参数进行了材料流动分析;观察到 1500 转/分钟时材料流动呈 "之 "字形混合,表明与 600 转/分钟相比,材料流动性更好。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
Numerical simulation of material flow and defect formation during FSW to predict weld failure location
Predicting the failure location of welded specimens is of importance for various industrial applications. In friction stir welding, material flow and eventually defect have an effect on the failure location. In the current work, a three-dimensional coupled Eulerian Lagrangian (CEL) is developed to study the material flow and predict defects originating during friction stir welding of AA2024 having a thickness of 3 mm. To minimize defects and achieve good weld quality, a square-shaped pin is used. The developed model is validated with experimentally observed axial force and spindle torque. Numerically predicted defects have been validated with experimental fracture locations and strength to test the robustness of the model in quantifying defects. Peak temperature increased by 10.7% when rotational speed was increased from 600 to 1500 rpm. Also, the peak temperature rise of 6.1% is observed when the welding speed is increased from 60 to 150 mm/min. Higher rotational and welding speed led to lower defects. At 1500 rpm and 150 mm/min process conditions, the highest weld strength of 447 MPa is obtained. Material flow analysis is carried out for varying process parameters; an intermixing of material flow with a zig-zag pattern is observed for 1500 rpm, indicating better material flow as compared with 600 rpm.
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来源期刊
CiteScore
5.10
自引率
30.80%
发文量
167
审稿时长
5.1 months
期刊介绍: Manufacturing industries throughout the world are changing very rapidly. New concepts and methods are being developed and exploited to enable efficient and effective manufacturing. Existing manufacturing processes are being improved to meet the requirements of lean and agile manufacturing. The aim of the Journal of Engineering Manufacture is to provide a focus for these developments in engineering manufacture by publishing original papers and review papers covering technological and scientific research, developments and management implementation in manufacturing. This journal is also peer reviewed. Contributions are welcomed in the broad areas of manufacturing processes, manufacturing technology and factory automation, digital manufacturing, design and manufacturing systems including management relevant to engineering manufacture. Of particular interest at the present time would be papers concerned with digital manufacturing, metrology enabled manufacturing, smart factory, additive manufacturing and composites as well as specialist manufacturing fields like nanotechnology, sustainable & clean manufacturing and bio-manufacturing. Articles may be Research Papers, Reviews, Technical Notes, or Short Communications.
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