Numerical Simulation In High-Frequency Induction Welding Of Copper-steel Based On ANSYS

In this paper, a mathematical model of magnetic field and the instantaneous temperature field is established based on the basic principle of induction heating, Maxwell’s equations and Joule’s law. ANSYS is used to simulate the temperature field of copper-steel high frequency induced deposition welding. With the experienced welding parameters, the welding process is simulated, so as to investigate the effect of these parameters on the induction heating and guide the actual welding.By controlling variable method, the individual parameter’s effect on the welding time and the influence of the temperature distribution in the workpiece are introduced. Different parameters of heating time, frequency of the power supply, diameter of the induction coil, the gap between the workpiece and the heating coil, the height and position of the heating coil are changed to analyze the effect of the above factors on the induction heating under the same conditions. The study found that the heating temperature of the workpiece rose faster at the beginning, then gradually achieve dynamic balance and temperature was getting steady. The position and diameter size of induction coil, current and current frequency have different impacts on induction deposition welding process.At the same time, welding parameters are set to practice the actual welding. In actual welding, the temperature of the point of steel substrate at the same height of the upper copper is measured and the temperature cycling curve is obtained at this point. Compared with the temperature of the point of welding simulation, the result is found to be within the error of 7.4% and the overall trend is the same. The shear strength of the joint is found 165MPa by the shear test to meet the requirements.