基于三维双塑性体摩擦副模型的FGH96高温合金管惯性摩擦焊数值模拟  

Numerical simulation of inertia friction welding of FGH96 superalloy tube based on 3D double plastic bodies friction pair model

作　　者：张广刚 赵强 刘佳涛 白瑞祥[1] 董红刚[1] Zhang Guanggang;Zhao Qiang;Liu Jiatao;Bai Ruixiang;Dong Honggang(Dalian University of Technology,Dalian 116024,Liaoning,China;Aero Engine Corporation of China,Shenyang 110043,China)

机构地区：[1]大连理工大学,辽宁大连116024 [2]中国航发沈阳黎明航空发动机有限责任公司,沈阳110043

出　　处：《焊接》2022年第7期14-20,共7页Welding & Joining

摘　　要：基于弹塑性有限元理论,采用三维塑性体/塑性体摩擦副模型,考虑实际焊接过程中两侧工件散热条件的差异,建立了FGH96高温合金管惯性摩擦焊过程有限元模型,计算了焊接过程中瞬态温度场和轴向应力场的分布,研究了初始转速、顶锻力和转动惯量对接头温度场和飞边形貌的影响。模拟的飞边形貌与试验所得焊件误差仅为5%,验证模型的可靠性。模拟结果表明,惯性摩擦焊过程中,摩擦界面升温迅速,峰值温度可达1335℃,塑性变形主要发生在距界面4 mm的区域内,该区域轴向温度梯度较大。摩擦界面附近压应力值从中心到边缘逐渐降低,界面边缘应力状态由压应力转变为拉应力,飞边根部由于挤压变形,存在压应力集中。提高初始转速和转动惯量均能增加焊接热输入,延长摩擦时间,提升峰值温度,增加飞边挤出量;加大顶锻力可提高机械能转化成热能的效率,缩短摩擦时间,增加轴向缩短量和飞边卷曲度。Based on elastic-plastic finite element theory,3D plastic body/plastic body friction pair model was used to establish a finite element model of inertia friction welding process of FGH96 superalloy tube by considering the difference in heat dissipation conditions on both sides of workpieces during actual welding process.Distribution of transient temperature field and axial stress field during welding was calculated.Effect of initial rotation speed,upsetting force and inertia moment on temperature field and flash morphology of welded joints was investigated.The error between simulated flash topography and test weldment was only 5%,which verified reliability of the model.The simulated results showed that during inertia friction welding process,friction interface was heated up rapidly,peak temperature could reach 1335℃,and plastic deformation mainly occurred in the area 4 mm away from interface,where the axial temperature gradient was large.The compressive stress value near friction interface gradually decreased from the center to the edge,stress state of interface edge changed from compressive stress to tensile stress,and root of the flash had compressive stress concentration due to extrusion deformation.Increasing initial speed and inertia moment could increase welding heat input,friction time,peak temperature and flash extrusion.Increasing upsetting force could improve efficiency of converting mechanical energy into thermal energy,shorten friction time,and raise axial shortening amount and flash curls.

关 键 词：惯性摩擦焊 数值模拟 温度场 轴向应力场 FGH96高温合金 

分 类 号：TG402[金属学及工艺—焊接]