电弧焊接数值模拟中热源模型的研究与发展
Research and development of a heat-source model in numerical simulations for the arc welding process
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摘要: 焊接过程的数值模拟作为一种有效的计算手段,在焊接温度场及残余应力分布的评价中获得了广泛应用,而焊接热源模型的选择及模型参数的确定直接影响到计算和评价结果的准确性.本文通过对近年来常用的电弧焊接热源模型进行梳理,介绍了其研究进展,分析了不同热源模型的特点及适用性.高斯面热源模型和双椭球体热源模型作为基础热源模型,广泛应用于较小尺寸工件和规则轨迹的焊接过程数值模拟,且具有较高的计算精度;简化热源模型和温度替代型热源模型多用于大厚工件的多层多道焊接及复杂轨迹焊接过程的数值模拟,能够实现效率和精度的统一;多丝电弧焊接热源较为复杂,采用修正后的双椭球体叠加热源模型,计算结果能保证一定的精度;结合型热源模型对熔池形状的描述更灵活,在深熔电弧焊的数值模拟中具有优势.本文可为电弧焊接过程数值模拟的热源模型选择和模型参数确定提供有益参考.Abstract: As an effective computational method, the numerical simulation of welding processes has been widely used in evaluating welding temperature fields and residual stress distributions. In the numerical simulation process, the selection of the welding heatsource model and the confirmation of model parameters will directly affect the accuracy of the calculation and the evaluation results. Some heat-source models commonly used in numerical simulations of the arc welding process were surveyed in this article; advances in their development were introduced, and their characteristics and applicability were analyzed. As basic heat-source models, the Gauss surface heat-source modes and double-ellipsoid-volume heat-source model have been widely used in the numerical simulation of arc welding for workpieces with a relatively small size and a regular welding trajectory, and the calculation results have been demonstrated to be accurate. In the numerical simulation of arc welding processes for large and thick workpieces welded using multi-layer or multipass techniques and for workpieces with a complex welding trajectory, the simplified heat-source model and temperature-substitution heat-source model are chiefly applied, and the calculation efficiency and precision can be well balanced. The heat source of multi-wire arc welding is comparatively complicated, and the superposed model of modified double-ellipsoid-volume heat-source models can ensure a certain accuracy of the calculation results. The combined heat-source model is more flexible in the shape description of the molten pool and has advantages in the numerical simulation of arc welding with deep penetration. The all-around induction and analyses in this article are expected to provide valuable reference and guidance for the selection of a heat-source model and for confirming model parameters in the numerical simulation of arc welding processes.