Performing an Indirect Coupled Numerical Simulation for Capacitor Discharge Welding of Aluminium Components
Performing an Indirect Coupled Numerical Simulation for Capacitor Discharge Welding of Aluminium Components
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DOI：
10.3390/pr8111330
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发表时间：
2020-10
期刊：
影响因子：
3.5
通讯作者：
Johannes Koal;M. Baumgarten;S. Heilmann;J. Zschetzsche;U. Füssel
中科院分区：
文献类型：
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作者：
Johannes Koal;M. Baumgarten;S. Heilmann;J. Zschetzsche;U. Füssel
用于凸焊的电容放电焊（CDW）在极短的焊接时间内提供非常高的电流脉冲。这需要在突起软化期间电极的快速跟踪行为。实验过程研究的可能性是非常有限的，因为覆盖的接触区和短的处理时间。有限元法（FEM）允许在时间和空间上进行高分辨率分析，因此是工艺表征和优化的合适工具。为了利用这种优化手段，在Ansys Mechanical APDL中开发了间接多物理数值模型。该模型将热电耦合的物理环境与结构分析相结合。它可以掌握大变形、短电流上升时间和高温度梯度的复杂性。一个典型的环投影已被选为连接任务。选择的铝合金是EN-AW-6082（环形凸起）和EN-AW-5083（金属板）。本文介绍了调查的材料数据，模型设计和方法的间接耦合的热电与结构热。在实验中，电接触电阻适应于测量的电压。Ansys Mechanical APDL中的模型限制是由于大的网格变形和降低的单元刚度。进一步建模的可能性，可以处理的限制，进行了说明。
Capacitor discharge welding (CDW) for projection welding provides very high current pulses in extremely short welding times. This requires a quick follow up behaviour of the electrodes during the softening of the projection. The possibilities of experimental process investigations are strongly limited because of the covered contact zone and short process times. The Finite Element Method (FEM) allows highly resoluted analyses in time and space and is therefore a suitable tool for process characterization and optimization. To utilize this mean of optimization, an indirect multiphysical numerical model has been developed in Ansys Mechanical APDL. This model couples the physical environments of thermal–electric with structural analysis. It can master the complexity of large deformations, short current rise times and high temperature gradients. A typical ring projection has been chosen as the joining task. The selected aluminium alloys are EN-AW-6082 (ring projection) and EN-AW-5083 (sheet metal). This paper presents the investigated material data, the model design and the methodology for an indirect coupling of the thermal–electric with the structural physic. The electrical contact resistance is adapted to the measured voltage in the experiment. The limits of the model in Ansys Mechanical APDL are due to large mesh deformation and decreasing element stiffness. Further modelling possibilities, which can handle the limits, are described.