毕业论文使用ANSYS有限元分析软件对不锈钢与紫铜焊接过程温度场应力场分布模拟教案.docxVIP

摘要太阳能热水系统中用到薄壁不锈钢与薄壁紫铜氩弧焊焊接。不锈钢与紫铜的焊接属于异种金属焊接，两者的物理性质差异很大，因而两者的焊接难度较大，在氩弧焊过程中易产生各种缺陷。本文通过ANSYS软件对其焊接过程进行了模拟，得到了薄壁不锈钢与薄壁紫铜焊接过程中的温度场、应力场分布，并依据模拟结果对焊接过程中可能出现的缺陷进行了分析。ANSYS模拟步骤如下：首先，确定薄壁不锈钢和薄壁紫铜氩弧焊工艺参数以及焊缝、坡口形状，为后文的模拟奠定基础；然后，建立焊接有限元模型，使用APDL语言编写热源施加程序，采用生死单元技术模拟焊接焊缝的依次生成，应用“*DO—*ENDDO”循环语句实现热源的移动，完成对焊接温度场的模拟和分析；最后，利用温度场与应力场间接耦合法，将温度场分析的结果温度作为载荷施加在模型上，模拟出焊接应力场，并对应力场模拟结果进行分析。根据焊接温度场、应力场模拟结果，本文分析了薄壁不锈钢与薄壁紫铜氩弧焊焊接过程中以及冷却后可能出现的质量缺陷，并提出了一些建议。具体结论和建议如下：一、由于紫铜散热比不锈钢快，因此薄壁不锈钢和薄壁紫铜焊接过程中两管的温度场分布极不均衡。这使得焊缝两侧基体金属熔化程度不一致，可能导致焊缝成形不良。建议在焊接时电弧稍微偏向紫铜管一侧，防止不锈钢一侧受热过多。二、冷却结束后，始焊位置和终焊位置结合处留有较大的残余应力，为253MPa，接近这一温度材料的屈服极限。因此，在焊接结合处会有较大的变形，其内部可能会出现较多的裂纹。建议在焊接时严格控制熔池温度、电弧大小以及氩气流量。三、由于在焊接过程中不锈钢管和紫铜管应力分布有很大的不同，因此在冷却结束后两管会产生不同的体积变化。这对于焊缝是不利的，同时也会使焊件不符合焊接前的尺寸公差，导致零件报废。建议焊前对焊件采取反应力、反变形措施。根据对焊件焊后应力场、焊件焊后变形的分析，本文对焊件进行了强度和变形校核，校核结果为：焊件合格，焊接可行。关键词：薄壁不锈钢和紫铜管；氩弧焊；ANSYS APDL；温度场；应力场；数值模拟AbstractTIG welding of thin-walled stainless steel and copper tubes is used in solar hot water system. As the welding of stainless steel and copper is dissimilar metal welding and their physical properties are very different, thus the welding of them is difficult and it is easy to produce a variety of defects in the TIG process. In this paper, the welding process of stainless steel with copper is simulated by using ANSYS software, and the temperature field, stress field distribution in the welding process is obtained afterwards, so that the defects that may occur during the welding process are analyzed based on the simulation results. ANSYS simulation steps are as follows:First, the TIG welding process parameters of thin-walled stainless steel and copper are determined with the shape of welding seam and groove, which lays foundation for later simulation;Then, the simulation and analysis of welding temperature field is completed by building a finite element model of welding, using APDL to make programs of heat source, applying element birth and death technology to simulate the successive generating of welding seams and adoptin