电机导条端环的感应焊接有限元分析  

Finite element analysis of induction welding of motor guide bar and end ring

作　　者：丁继聪 石武平 陈仕奇 唐华平[1] DING Jicong;SHI Wuping;CHEN Shiqi;TANG Huaping

机构地区：[1]中南大学机电工程学院,湖南长沙410083

出　　处：《现代机械》2020年第3期6-12,共7页Modern Machinery

摘　　要：感应焊接工艺所带来的残余应力降低了电机焊接部位的强度,针对该感应焊接的工艺过程和工艺参数进行简化模拟仿真,得到了焊后残余应力场。借助ABAQUS仿真软件对简化后的电机几何模型建立旋转周期对称有限元模型,然后利用生死单元技术模拟焊料填充导条与端环缝隙的加热过程和焊后冷却至室温的过程。仿真后可知:用ABAQUS软件可以对电机感应焊接整个制造工艺进行全过程模拟,并得到各部件的焊后残余应力场。其中,导条与端环之间的初始安装间隙量δ和焊接顺序共同影响导条和焊料各应力大小,而导条径向应力分量S11对于间隙量δ改变的敏感度最大。综合导条和焊料各应力值大小及敏感度,得到间隙量δ变化范围在0.40~0.60 mm时,导条和焊料的应力值变化率控制在5%以内,且应力值较小。随着焊接的进行,焊接B端后可使A端的应力最大值减小,而在焊接B端后,A端和B端的应力值大小比较随间隙量的大小而定。The residual stress brought by the induction welding process would reduce the strength of the welding parts of the motor.Aiming at the problem,a simplified simulation of the process and parameters of the induction welding was performed to obtain the residual stress field after welding.With the help of ABAQUS simulation software,a symmetric finite element model of the rotation period of the simplified motor geometric model was established,and the birth-death element technology was used to simulate the heating process of solder filling the gap between the guide bar and the end ring and the cooling process after welding.The results showed that the entire induction welding process could be simulated by using ABAQUS software,and the post-weld residual stress field of each component could be obtained.The initial installation gap amountδbetween the guide bar and the end ring and the welding sequence jointly affected the stress of the guide bar and the solder,and the radial stress component S11 of the guide bar was the most sensitive to the change of the gap amountδ.When the variation range of the gap amountδwas between 0.40 mm and 0.60 mm,the change rate of the stress value of the guide bar and the solder was controlled within 5%,and the stress value was small.With the progress of welding,the maximum value of the stress at A end could be reduced after B end was welded.After B end was welded,the stress values at A end and B end would depend on the gap amount.

关 键 词：感应焊接 残余应力 工艺参数 ABAQUS 生死单元 

分 类 号：TG4[金属学及工艺—焊接]