Simulation Analysis And Process Optimization Of Aluminum Alloy Anti-collision Beam Welding Based On ABAQUS

In recent years,the automobile industry has a global tendency to use more and more light metal material.The aluminum alloy has perfect properties to satisfy the light weight.However,compared with conventional steel,alum inum alloy has poor weldability,which results in greater local stress and welding def ormation during welding process.Furthermore,these defects greatly pull down the quality and accuracy of welded parts.Numerical simulation of aluminum alloy welding process and welding deformation temperature field can effectively control the whole welding deformation and stress distribution.In this paper,based on ABAQUS software,an efficient pretreatment method for numerical simulation of temperature field in MIG welding of aluminum alloy T-shaped plate is developed.The double ellipsoid heat source distribution function is selected to simulate the welding heat source in the process of aluminum alloy MIG welding.The DFLUX welding heat source subroutine is written by F ORTRAN.The parameters such as the generation process of welding seam and material p roperties are automatically set by Python in the process of aluminum alloy T-shaped plate MIG welding temperature field simulation.The pretreatment process of aluminum alloy welding temperature field simulation is completed quickly.Secondly,the welding test of T-shaped aluminum alloy plate is tested to ensure the quality of the weldment and the performance of the welding joint,and the best process parameters of 3 mm thick T-shaped aluminum alloy plate are determined.The optimal process parameters are used as the basis for setting the heat source model parameters in the simulation process of aluminum alloy T-shaped plate welding,and the temperature field distribution in the welding process is calculated by the established temperature model.At the same time,the temperature cycle curves of different sizes in the process of MIG welding of aluminum alloy T-shaped plate are measured by thermocouple,and the accuracy of the simulation results of temperature field of aluminum alloy T-shaped plate welding is verified by comparing with the simulation temperature cycle curve.Then,the pre-processing method of welding temperature field simulation of aluminum alloy T-shaped plate is applied to the simulation analysis of temperature field of MIG welding of aluminum alloy anti-collision beam,and the results of temperature field in the welding process are obtained.Using the method of sequence coupling,the welding deformation of the energy absorbing box of the anti-collision beam is calculated by taking the calculat ion result of the temperature field as the load of the welding deformation analysis.The accuracy of the simulation results of the welding deformation of the aluminum alloy anti-collision beam is verified by the experimental results of three coordinate sampling.Finally,on the basis of ensuring the accuracy of simulation calculation of welding deformation of aluminum alloy anti-collision beam,the optimization of welding process scheme of aluminum alloy anti-collision beam is completed.The welding deformation of energy absorption box after welding of aluminum alloy anti-collision beam is obtained under different welding process parameters.By comparing the results of each optimization scheme,it can be concluded that the optimal welding process is to continuously weld the short welds of the energy absorbing box on one side of the anti-collision beam,and to symmetrically weld the long welds of the energy absorbing box on both ends.The scheme can not only meet the requirements of post welding deformation,but also effectively reduce the action path of welding gun in the whole welding process.It can effectively reduce the welding deformation and provide some guidance for the actual production process.