Stress and Strain Analysis of Aluminum/Steel Continuous Drive Friction Welding Joints Under Thermal Cycling

ZHANG Changqing; WANG Ye; SHI Yu; MA Dongdong; GU Huaizhuang

doi:10.7512/j.issn.1001-2303.2024.02.04

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Stress and Strain Analysis of Aluminum/Steel Continuous Drive Friction Welding Joints Under Thermal Cycling
Vol. 54, Issue 2, Pages: 24-29(2024)
DOI： 10.7512/j.issn.1001-2303.2024.02.04

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张昌青，王烨，史煜，等.热循环下铝/钢连续驱动摩擦焊接接头应力应变分析［J］.电焊机，2024，54（2）：24-29.

ZHANG Changqing, WANG Ye, SHI Yu, et al.Stress and Strain Analysis of Aluminum/Steel Continuous Drive Friction Welding Joints Under Thermal Cycling[J].Electric Welding Machine, 2024, 54(2): 24-29.
张昌青，王烨，史煜，等.热循环下铝/钢连续驱动摩擦焊接接头应力应变分析［J］.电焊机，2024，54（2）：24-29. DOI： 10.7512/j.issn.1001-2303.2024.02.04.

ZHANG Changqing, WANG Ye, SHI Yu, et al.Stress and Strain Analysis of Aluminum/Steel Continuous Drive Friction Welding Joints Under Thermal Cycling[J].Electric Welding Machine, 2024, 54(2): 24-29. DOI： 10.7512/j.issn.1001-2303.2024.02.04.

摘要

利用ABAQUS有限元软件，建立了一个新的连续驱动摩擦焊接头热-力耦合过程的数值模型，分析了试验过程接头温度场、应力应变分布规律，通过与实际试验结果的对比，验证模型的准确性。得出如下结论：热循环过程中，冷却及低温保温过程是热应力最大的阶段；接头颈缩形貌和产生位置与试验结果吻合较好，颈缩位置与实际试验相对误差为6%，颈缩现象的本质是铝在自由膨胀收缩时应力超过强度极限产生的塑性变形。在拉伸断口观察到解理断裂圆环，其位置、宽度与模拟结果的应变集中区域吻合度高。该模型较准确的模拟了连续驱动摩擦焊接头的热-力耦合过程，为实际生产和工艺优化提供了有力支持。

Abstract

Using ABAQUS finite element software

a new numerical model of thermal mechanical coupling process of continuously driven friction welded joints was established. The following conclusion is drawn: the cooling and low-temperature insulation processes during the thermal cycle are the stages with the highest thermal stress; The appearance and location of joint necking are in good agreement with the experimental results

and the relative error between the necking location and the actual experiment is 6%. The essence of the necking phenomenon is the plastic deformation caused by the stress exceeding the strength limit when the aluminum is Free expansion and shrinkage; The cleavage fracture ring was observed on the tensile fracture surface

and its position and width are highly consistent with the strain concentration area of the simulation results.The numerical model accurately simulates the thermo-force coupling process of continuously driven friction welded joints

which provides strong support for actual production and process optimaztion.

关键词

连续驱动摩擦焊接热循环热应力有限元模拟应力应变场

Keywords

continuous drive friction weldingthermal cyclingthermal stressfinite element simulationstress and strain field

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