5052铝合金电阻点焊电极形状对电极寿命的影响
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摘要
利用ANSYS软件建立了直径分别为6和8 mm的锥台电极和直径16 mm的球电极所对应的5052铝合金电阻点焊过程的有限元模型,分析了在相同的焊接工艺参数下3种类型电极几何形状对5052铝合金电阻点焊的熔核形成过程及其焊接质量和电极自身磨损的影响,并通过连续点焊试验验证了模型的准确性.结果表明:对于锥台电极,在相同的焊接电流条件下,电极端面直径越小,所得到的熔核尺寸越大,点焊接头质量越好;球电极与工件的接触面积过小,将会使得电流集中、温度过高而发生严重的电极烧损.所建模型的模拟结果与试验结果的误差在4%以内,采用直径6 mm的锥台电极进行5052铝合金薄板焊接时,电极寿命比球电极提高了20%.
Numerical simulations of resistance spot welding with different electrode(?6 mm, ?8 mm cone electrodes, and ?16 mm ball electrode) were performed by ANSYS to examine the effect of the nugget shape on the weld properties and the service life of the electrodes under the same parameters. Continuous spot welding is carried to verify the correctness of the finite model. The results indicate that as for the cone electrode, the smaller the diameter of the electrode is, the larger the size of the nugget, and the weld joint has good performance. The contact area between the ball electrode and the work piece is too small and the joule heat generated is large. So, the ignition loss of electrodes is a crucial problem for the ball electrode. The simulation results are in good agreement with the metallographic results. The service life is improved by 20% compared with the ball electrode when the 5052 thin plate is welded by ?6 mm cone electrode, which provides the theoretical basis for selecting the electrode shape.
Numerical simulations of resistance spot welding with different electrode(?6 mm, ?8 mm cone electrodes, and ?16 mm ball electrode) were performed by ANSYS to examine the effect of the nugget shape on the weld properties and the service life of the electrodes under the same parameters. Continuous spot welding is carried to verify the correctness of the finite model. The results indicate that as for the cone electrode, the smaller the diameter of the electrode is, the larger the size of the nugget, and the weld joint has good performance. The contact area between the ball electrode and the work piece is too small and the joule heat generated is large. So, the ignition loss of electrodes is a crucial problem for the ball electrode. The simulation results are in good agreement with the metallographic results. The service life is improved by 20% compared with the ball electrode when the 5052 thin plate is welded by ?6 mm cone electrode, which provides the theoretical basis for selecting the electrode shape.
引文
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[12] WANG J,WANG H P,LU F G,et al.Analysis of Al-steel resistance spot welding process by developing a fully coupled multi-physics simulation mode[J].International Journal of Heat and Mass Transfer,2015,89:1061-1072.
[2] 于汇泳,周慧琳,刘丹.铝合金点焊电极复合涂层的制备[J].热加工工艺,2013,42(15):196-197.YU Huiyong,ZHOU Huilin,LIU Dan.Preparation of compound coating on aluminum alloy spot welding compound coating[J].Hot Working Technology,2013,42(15):196-197.
[3] LUO P,DONG S J,XIE Z X,et al.The effects of coating parameters on the quality of TiB2-TiC composite phase coating on the surface of Cu-Cr-Zr alloy electrode[J].Surface & Coatings Technology,2014,253:132-138.
[4] 蔡军,梅秀山,蔡峰.汽车用铝合金/高强钢异种材料电阻点焊过程数值模拟[J].电焊机,2015,45(7):13-18.CAI Jun,MEI Xiushan,CAI Feng.Numerical simulation of the resistance spot welding process of aluminum alloy and high-strength steel dissimilar materials for automobile[J].Electric Welding Machine,2015,45(7):13-18.
[5] 杨凤霞,曹克浩.基于ANSYS汽车用镁合金电阻点焊熔核形成过程温度场计算机数值模拟研究[J].热加工工艺,2016,45(3):233-236.YANG Fengxia,CAO Kehao.Numerical simulation on temperature filed during resistance spot welding of magnesium alloy based on ANSYS[J].Hot Working Technology,2016,45(3):233-236.
[6] LI Y B,WEI Z Y,LI Y T,et al.Effects of cone angle of truncated electrode on heat and mass transfer in resistance spot welding[J].International Journal of Heat & Mass Transfer,2013,65(7):400-408.
[7] 洪小英.5052 铝合金连续铸轧过程温度场与速度场的模拟[J].热加工工艺,2015,44(15):84-86.HONG Xiaoying.Numerical simulation of temperature and velocity field in continuous cast rolling process of 5052 aluminum alloy[J].Hot Working Technology,2015,44(15):84-86.
[8] 黄伯云.有色金属材料手册[M].北京:化学工业出版社,2009:110-112.HUANG Boyun.Nonferrous metals materials hangbook[M].Beijing:Chemical Industry Press,2009:110-112.
[9] 彭建,王永建,钟丽萍,等.5052 铝合金板材热轧过程塑性变形及应力分布的三维热力耦合模拟[J].材料热处理学报,2015,36(3):209-213.PENG Jian,WANG Yongjian,ZHONG Liping,et al.Three dimensional thermal mechanical coupled simulation of plastic deformation and stress distribution during hot rolling of 5052 aluminium sheet [J].Transactions of Materials and Heat Treatment,2015,36(3):209-213.
[10] KAMMER C.铝手册[M].卢惠民译.北京:化学工业出版社,2009:58-60.KAMMER C.Aluminium handbook[M].Translated by LU Huimin.Beijing:Chemical Industry Press,2009:58-60.
[11] BERGER H H.Contact resistance and contact resistivity [J].Journal of The Electrochemical Society,1972,119(4):507-514.
[12] WANG J,WANG H P,LU F G,et al.Analysis of Al-steel resistance spot welding process by developing a fully coupled multi-physics simulation mode[J].International Journal of Heat and Mass Transfer,2015,89:1061-1072.
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