Numerical Simulation Of Temperature Field And Residual Stress Field Of Axial Vibration Consumable Friction Welding

Consumable friction welding is a solid surface engineering technology which began in the middle of the last century,and formally sprung up in twenty-first Century.It is a potential welding process that conforms to the advanced manufacturing idea of high efficiency and cleanliness in the new era,and has incomparable advantages in repairing and reforming worn and damaged parts.Consumable friction welding can be used to modify the surface of metal material structure and refine the grain size and obtain good wear resistance and corrosion resistance cladding layer.In addition,it can realized the welding between dissimilar metals and difficult to weld materials.In this paper,6061 aluminium alloy is taken as the research object.The heat generation and transfer mechanism of friction surface,stress and strain of material are deeply studied.At the same time,on the basis of common consumable friction welding of at home and abroad,consumable friction welding with axial vibration on consumable rod is proposed.The heat generation mechanism of consumable friction welding is expounded,and the friction model between consumable rod and welding plate is established by Coulomb friction law.The reasonable assumption and simplification of welding process are made.The temperature field and residual stress field of consumable friction welding were analyzed by ANSYS and MATLAB.The peak temperature of the weldment is between 0.5R and 0.8R in the contact area between the consumable rod and the weldment,and the temperature in front of the consumable rod is lower than that in back.After cooling,the residual stress on the weldment mainly concentrates in the vicinity of the weld seam,and the longitudinal residual stress is the main form of stress,while the transverse and thickness residual stress is smaller.On the basis of the above analysis,the axial vibration is added to the consumable rod by using the function self-definition function of ANSYS.The influence of the added vibration on the temperature field and residual stress field is analyzed,and the comparison is made between the non-vibration consumable friction welding.It is concluded that under the same process parameters,vibration increases the peak temperature of the weldment and decreases the residual stress of the weldment.Finally,the influence of welding speed,rotational speed and consumable rod diameter on axial vibration consumable friction welding of is studied by variable control method,and the influence of different amplitudes and frequencies on temperature field and residual stress field in welding process is discussed.The results show that the peak temperature increases with the increase of rotational speed and diameter of consumable rod,decreases with the increase of welding speed,and the residual stress increases with the increase of rotational speed and welding speed,and decreases first and then increases with the increase of diameter of consumable rod.The temperature and residual stress of the weldment increase with the increase of amplitude and frequency.The content of this paper provides theoretical guidance and reference value for the selection of engineering application technical parameters.