基于风场的GMAW焊接电弧与熔池行为数值模拟研究

    Numerical Simulation Study of Arc and Molten Pool Behavior in GMAW Welding Based on Wind Field

    • 摘要: 为揭示风场环境对熔化极气体保护焊(GMAW)焊接过程中电弧与熔池行为的影响机理,考虑标准k-ε湍流模型,建立电弧与熔池耦合的三维瞬态模型,对比分析垂直于焊接方向的侧向风场强度大小对电弧形态以及熔池形貌的影响规律。结果表明:侧向风场环境下,电弧等离子体的运动轨迹和速度发生变化,过大的侧向风场还削弱保护气体的保护效能,提高焊缝中气孔缺陷的形成风险;风场强度的提高使电弧弧长增加、散热速率加快,导致其对工件的热输入量降低,熔池形状尺寸变小。通过对比仿真结果与焊接实验拍摄的电弧形态和熔池形貌,验证了模型的可靠性。

       

      Abstract: To reveal the influence mechanism of crosswind conditions on arc and molten pool behavior during the gas metal arc welding(GMAW) process, a three-dimensional transient model of arc and molten pool coupling was established using the standard k-ε turbulence model. A comparative analysis was conducted on the effects of varying crosswind intensities perpendicular to the welding direction on arc morphology and molten pool morphology. The results show that under crosswind conditions, the arc plasma’s trajectory and velocity change. Stronger crosswinds weakens the protective efficiency of the shielding gas, leading to the formation of vortices in the welding area and increasing the risk of porosity defects. The increase of wind field strength increases the arc length and accelerates the heat dissipation rate, leading to the decrease of the heat input to the workpiece and the smaller shape and size of the molten pool. The reliability of the model is verified by comparing the simulation results and arc morphology and pool morphology captured by welding test.

       

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