Finite Element Analysis Of Rail Flash Welding Based On ABAQUS

The development of the seamless line is one of the important factors affecting the development of the railway transportation.The quality of welded joints of seamless lines is an important factor to ensure the normal operation of seamless lines.Flash welding is the most widely used method for seamless line welding.The protection of welded joint in flash welding;distribution of temperature field in high temperature zone of rail before upset;the process parameters in upset process are the most important factors to influent the quality of welded joint.It's too complicated and expensive to satisfy the quality requirements by debugged the process parameters,because there're too many parameters affecting those three factors.So build the flash welding welded joint finite element analysis model to study the influencing factors and regularities of temperature field of welded joints for providing the guidance in process parameters debugging and reducing the cost investment during the debugging.Based on these background,this paper carried out the following work:(1)Built the 60Kg/m U75 V rail flash process thermos-electric coupling model in flash welding,by using ABAQUS software.Simulation the rail burning in flash welding by using “model change” function in ABAQUS.It was perfectly solved the simulation of contact resistance and material burning out in flash welding.Using the thermocouple temperature measurement to verify the model was correct;(2)Calculation the temperature field distribution of welded joints of rails with different burning speeds,by the flash process thermos-electric coupling model.Combining the analysis result and related literatures,summarized the influence of burning speed on distribution of temperature field and provided some suggestions for process debugging of rail flash welding in flash process;(3)Built the 60Kg/m U75 V rail upset process thermos-mechanical coupling model in flash welding,by using ABAQUS software.Using the quasi-static criteria and morphology comparison test to verify the model was correct.Preliminary studied on the extrusion of residual impurities(gray spots)during flashing in different initial upset temperatures and different upset velocities.Finally provided some suggestions for the selection of the temperature field before flash upsetting and the upsetting speed during upsetting.The models constructed in this paper runs through the entire processes of rail flash welding,providing new ideas for the debugging of rail flash welding and saving a lot of tedious test time.