基于CEL方法攪拌摩擦焊材料流動及缺陷的模擬

基于CEL方法攪拌摩擦焊材料流動及缺陷的模擬Simulation on material flow and defect during friction stir welding based on CEL method

基于歐拉-拉格朗日耦合(CEL)方法，建立一個新的攪拌摩擦焊多場耦合計算模型，模擬焊接過程中焊縫區(qū)材料的塑性流動與缺陷形成，并通過開展攪拌摩擦焊試驗，分別從溫度場、焊縫宏觀形貌、焊縫截面塑性應變及焊接缺陷幾方面對模擬結(jié)果的準確性進行驗證。結(jié)果表明：模擬溫度與實測數(shù)據(jù)吻合較好，最大誤差為23.4 ℃；焊縫宏觀形貌、焊縫截面塑性應變區(qū)的形狀和尺寸均與實際焊縫吻合較好；模型能夠較準確地預測焊縫內(nèi)部孔洞缺陷的形成，且缺陷產(chǎn)生的位置與實際位置相吻合，缺陷尺寸的模擬值略大于其實測值。

A new multi-physics coupling numerical model for friction stir welding was established based on coupled Eulerian-Lagrangian (CEL) method. The model was utilized to simulate the material flow and defect formation in the weld during welding. The friction stir welding was conducted to verify the model through the comparison of temperature field, macro morphology of weld, plastic strain in the weld and welding defect. The results show that the simulation temperatures agree well with the measured data and the maximum error is 23.4 ℃. The macro morphology of the weld, the plastic strain zone shape and size on the weld cross-section are in good agreement with the actual weld. The model can accurately predict the formation of void defect in the weld, and the simulated void position is consistent with the actual position. But the void size is overestimated slightly.

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