焊接工艺对汽车控制臂焊接变形的影响

王大锋; 张广和; 胡全达; 任政; 姜彤

doi:10.7513/j.issn.1004-7638.2023.02.025

焊接工艺对汽车控制臂焊接变形的影响

doi: 10.7513/j.issn.1004-7638.2023.02.025

1.
中国兵器科学研究院宁波分院, 浙江宁波 315103
2.
浙江锐泰悬挂系统科技有限公司, 浙江宁波 315502

基金项目: 国家自然科学基金（51901236）；宁波市科技攻关计划项目（2022Z073）；企业技术开发项目（2021330200000763）；中国兵器工业集团第五二所所列基金（NBFJ2022-07）。

详细信息

作者简介:
王大锋，1987年出生，男，安徽阜阳人，博士研究生，副研究员，长期从事高能复合焊接与表面工程技术研究工作，E-mail:bjing2013saw@126.com

中图分类号: TG444
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出版历程
- 收稿日期: 2022-11-08
- 刊出日期: 2023-04-30

Effect of welding process on welding deformation of automobile control arm

1.
Ningbo Branch of China Ordnance Research Institute, Ningbo 315103, Zhejiang, China
2.
Zhejiang Ruitai Suspension System Co., Ltd., Ningbo 315502, Zhejiang, China

摘要

摘要: 以汽车控制臂焊接构件作为研究对象，利用SYSWELD软件对控制臂构件的焊接热输入和焊接顺序进行优化。结果表明：当焊接热输入偏小时（2015～2266 J/cm），控制臂上下片之间的角焊缝焊根位置会出现未焊透缺陷；当焊接热输入适中时（2527～2701 J/cm），角焊缝能获得较好的焊缝熔宽和熔深。此外，对比分析不同焊接顺序下控制臂的残余应力和变形，发现采用先中间后两边（①④③⑤⑥②⑦⑧）的焊接顺序有利于降低控制臂整体的残余应力峰值；采用其它的焊接顺序时，控制臂整体的残余应力峰值较高，焊接变形也较大。试验与仿真结果对比表明，仿真结果的准确性较高，利用有限元仿真能优化汽车控制臂的焊接工艺，提高控制臂产品的焊接质量。
- 汽车控制臂 /
- 焊接变形 /
- SYSWELD /
- 有限元仿真
Abstract: Taking the control arm welding component of automobile parts factory as the research object, a SYSWELD software is used to optimize the welding heat input and welding sequence of control arm components. The results show that when the welding heat input is too low (2015～2266 J/cm), incomplete penetration will occur at the root of the fillet weld between the upper and lower pieces of the control arm. When the welding heat input is moderate (2527～2701 J/cm), the fillet weld can obtain better weld penetration width and penetration depth. In addition, by comparing and analyzing residual stress and deformation atcontrol arm under different welding sequences, it is found out that the welding sequence from the middle to the two sides (①④③⑤⑥②⑦⑧) is conducive to reducing peak residual stress of control arm as a whole. When other welding sequences are used, the peak residual stress and residual deformation of control arm are high. The comparison between the experimental and simulation results indicates that the accuracy of the simulation results is high. The finite element simulation can be used to optimize the welding process of the automobile control arm and improve the welding quality of the control arm products.
- automobile control arm /
- welding deformation /
- SYSWELD /
- finite element simulation

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图 1 控制臂构件的CAE模型

Figure 1. The CAE model of control arm

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图 2 控制臂构件的温度场模型

Figure 2. Temperature field model of control arm

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图 3 控制臂构件的焊缝示意

Figure 3. Schematic diagram of welds of control arm

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图 4 正交试验焊接接头温度场分布

（a）～（i）对应试验号1～9

Figure 4. Temperature field distribution at welding joint for orthogonal experiment

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图 5 正交试验焊接接头变形场分布

（a）～（i）对应试验号1～9

Figure 5. Deformation field distribution at welding joint for orthogonal experiment

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图 6 不同焊接顺序下控制臂构件的残余应力分布

（a）～（d）分别为方案1～4

Figure 6. Residual stress distribution in control arm with different welding sequence

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图 7 不同焊接顺序下控制臂构件的变形分布

（a）～（d）分别为方案1～4

Figure 7. Deformation distribution in control arm with different welding sequence

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表 1 FB60钢化学成分

Table 1. Mass fraction of elements in FB60 steel %

C	Si	Mn	P	S	Cr	Ni	Mo	Nb	V	Fe
0.081	0.078	1.45	0.014	0.04	0.038	0.016	0.02	0.027	<0.01	Bal.

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表 2 FB60钢的性能参数

Table 2. Performance parameters of FB60 steel

温度 /℃	密度 / (kg·m⁻³)	导热率 / (W·m⁻¹ ·K⁻¹)	比热容 / (J·kg⁻¹ ·K⁻¹)	弹性模量 / GPa	泊松比	热膨胀系数 / ℃⁻¹
25	7.85	70.6	440	33.8	0.289	8.72×10⁻⁶
100	7.85	65	445		0.292	11.8×10⁻⁶
200	7.85	60	450		0.296	13.2×10⁻⁶
300	7.85	55.6	452	118.6	0.3	14.1×10⁻⁶
400	7.85	50	400		0.304	14.8×10⁻⁶
500	7.85	47	350		0.308	15.1×10⁻⁶
600	7.85	42.9	298	30.3	0.321	15.2×10⁻⁶
700	7.85	40	250	30.3	0.329	15.2×10⁻⁶
900	7.85	37.8	108	3.47	0.345	11.9×10⁻⁶
1100	7.85	37	120	3.47	0.351	13.7×10⁻⁶

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表 3 正交试验参数

Table 3. Orthogonal experimental parameters

编号	试验方案	（A)焊接电压/V	(B)焊接电流/A	(C)焊接速度/(m·s⁻¹)	热输入/ (J·cm⁻¹)	接头质量
1	A₁B₁C₁	18	155	0.008	2266	未焊透
2	A₁B₂C₂	18	165	0.009	2145	未焊透
3	A₁B₃C₃	18	175	0.010	2047	未焊透
4	A₂B₁C₂	19	155	0.009	2126	未焊透
5	A₂B₂C₃	19	165	0.010	2037	未焊透
6	A₂B₃C₁	19	175	0.008	2701	完全焊透
7	A₃B₁C₃	20	155	0.010	2015	未焊透
8	A₃B₂C₁	20	165	0.008	2681	完全焊透
9	A₃B₃C₂	20	175	0.009	2527	完全焊透

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表 4 施焊顺序方案

Table 4. Welding sequence scheme

编号	焊接顺序
方案1	①②③④⑤⑥⑦⑧
方案2	①④②⑥⑤③⑦⑧
方案3	①④③⑤⑥②⑦⑧
方案4	②③⑤⑥①④⑦⑧

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表 5 试验和模拟结果对比

Table 5. Comparison of experimental and simulation results

编号	控制臂最大残余应力/MPa	控制臂最大残余变形/mm
计算仿真	568	0.41
实际焊接	536	0.39

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