| Consumable-rod friction welding(CFW)is an advanced material processing technology which makes use of friction heat to make the local welding area of materials in a thermo-viscoplastic state to realize welding.It has the advantages of low energy consumption,high efficiency and green manufacturing.This process is a complex process in which temperature change,microstructure transformation,stress-strain and metal flow are coupled and interact with each other.The numerical simulation of temperature and stress fields in consumable-rod friction welding is very important for optimizing welding parameters and guaranteeing weld quality.In this paper,based on ANSYS finite element analysis software,the thermo-mechanical coupling model of Consumable-rod friction welding is established.The welding process is reasonably assumed and simplified,a reasonable heat source model is established.The whole welding physical process is simulated and calculated by using the life-and-death element technology and moving heat source loading,Analyzing the cloud field distribution and curve change of temperature field and stress field.During steady-state welding,the temperature remains stable with slight fluctuations,and the residual stress at the weld increases during the cooling process.By changing the welding parameters,such as the rotating speed of consumable rod,welding traveling speed,axial pressure,width and thickness of welding workpiece,the influence mechanism of different parameters on the welding process was studied.The influence of welding parameters on temperature and stress fields was analyzed by single factor method.The axial pressure and the rotational speed have a great influence on the temperature field and the residual stress,and the influence of the traveling speed is relatively small.The thickness of the welded workpiece has a large influence on the temperature field,which affects both the peak temperature and the heat dissipation process.The width of the welded workpiece affects the heat dissipation of the entire welding system during the cooling process.In order to obtain good welding quality,the welding process parameters need to match each other,and different geometric dimensions of the welding workpiece correspond to different dynamic parameters of the welding system.The friction welding process of consumable-rod friction welding with two welds was numerically simulated,studying the interaction mechanism of two welds.And the effects of different welding paths(parallel welding and U-type welding)on the temperature and stress fields were analyzed.The distribution rule and peak value change of residual stress of welded workpiece under different welding paths are compared and analyzed.The residual stress of U-shaped welding is greater than that of side-by-side welding,and the residual stress peak is located at the initial welding position of the second weld.The difference of residual stress in different regions is greater by U-type welding.It is easy to deform and is not conducive to the dimensional stability of the workpiece.The whole physical welding process of consumable-rod friction welding is simulated and calculated.The influence of each process parameter on the welding process was analyzed,and the distribution and peak value of residual stress were compared between the two welds in different welding paths.Numerical simulation provides a theoretical basis for practical production and application,which is of great significance for optimizing welding process and improving welding quality. |
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