Research On Complete Thermal-force Coupling During Friction Welding Of Ultrasonic Vibration Consumables

Consumable friction welding(CFW)live is a kind of energy conservation,environmental protection and efficient green pollution-free solid-phase remanufacturing technology,at present is mainly used for solving the problem of the corrosion such as surface repair worn parts,in terms of wear parts manufacture and repair welding process will have wide applications in the future depend on axial pressure and rotation speed of the friction heat to make materials produce thermoplastic deformation,therefore the research of the welding process temperature plasticity change rule and the influence of welding parameters on weld quality is particularly important,on the other hand thermoplastic deformation of a high pressure and large speed welding load is too large,makes the welding process less flexibleIn order to solve the above problems,the thermal softening effect of ultrasonic vibration on materials is proposed to reduce the welding load and accelerate the welding speed.(1)In the first place of the traditional consumable friction welding process in thermodynamic coupling model,using the nonlinear finite element software ABAQUS,the coupled thermo-mechanical analysis research status,clear heat coupling analysis of the specific research contents,application of ALE grid adaptive technology to solve due to the material friction welding mesh distortion problems caused by the highly nonlinear,and the simulation results verified.(2)According to the result of simulation and analysis of welding temperature field of equivalent plastic strain field in the process of flash shape and quantity of the axial shortening,etc.,and in many aspects in this paper,the thermodynamic changes after welding process,the use of single variable method to study the effect of welding process parameters on the welding parameters,the results show that the material friction welding process temperature is lower than the material melting point of solid phase connection,metal fully softened by the same flash extrusion forming mushroom head,temperature is higher than the back side of the forward side,consumables bar high temperature region is greater than the substrate temperature region;After the high temperature region becomes stable,the consumable bar has obvious deformation,and the axial shortening and time show a nearly linear relationship.The change of process parameters has different influence on the temperature plastic deformation and consumptive rate of consumable rod.(3)On the basis of traditional material friction welding model,using the softening effect of ultrasonic vibration,adding high frequency vibration,ultrasonic vibration consumable friction welding thermal coupling model is established,the quantitative analysis of the thermodynamic changes of ultrasonic welding process behavior,compared to two kinds of welding temperature under the condition of plastic strain change rule of welding speed,and the analysis of the effect of different amplitude frequency on three kinds of physical quantities,the results showed that the ultrasonic vibration can reduce the peak temperature of welding,expand the welding heat affected zone,intensifying material plastic flow,speed up the consumption of consumables bar rate,improve the welding speed,to obtain a better welding quality.(4)The axial feeding way of welding,focusing on the research of the welding process load first analysis the changes of different feeding speed and the influence of the rotational speed of the welding load,on the basis of the analysis of ultrasonic vibration on the welding process,the influence of axial load according to the results of the simulation to get the load variation curve of welding process,show that ultrasonic vibration can reduce the load of welding,and the softening effect of ultrasonic vibration will change as for the welding,the increase of the vibration parameters can be reduced to a increase of axial load.