A process parameter simulation optimization method for high-frequency induction brazing

Abstract

A method for simulating and optimizing process parameters for high-frequency induction brazing is proposed. First, a finite element model of the part to be welded is established. Then, the heating method for high-frequency induction brazing is simulated using the heat treatment module of Sysweld software. Multiple simulated temperatures between the melting points of the brazing filler metal and the part to be welded are selected and input into Sysweld software to calculate the welding stress cloud diagrams corresponding to these simulated temperatures. The maximum welding stress values ​​corresponding to each of the multiple simulated temperatures are then obtained. The value with the smallest value is selected as the optimal welding stress value. The simulated temperature corresponding to the optimal welding stress value is then selected as the optimal simulated temperature. A high-frequency induction brazing experiment is conducted on the part to be welded at the optimal simulated temperature to obtain the maximum test stress value. The optimal welding stress value is compared with the maximum test stress value. If both meet the error requirement, the optimal simulated temperature is used as the process parameter for high-frequency induction brazing; otherwise, a new simulated temperature is selected.

Description

Technical Field

[0001] This invention relates to the field of high-frequency induction brazing, and more particularly to a method for simulating and optimizing process parameters in high-frequency induction brazing. Background Technology

[0002] High-frequency induction brazing is a welding method that utilizes the eddy current effect on the workpiece in an alternating magnetic field and electric field to heat the base material, causing the solder to melt. Once liquefied, the solder fills the gaps under capillary action, thus achieving brazing. High-frequency induction brazing uses high-frequency alternating current to achieve the welding process. To achieve ideal brazing results, it is essential to ensure the melting, distribution, and uniformity of the solder. This involves the acquisition and control of heat and temperature. The precise control of the coil induction frequency and temperature field is crucial for the heat and temperature distribution acquired at different locations within the solder.

[0003] Current research on high-frequency induction brazing technology generally relies on extensive trial and error, which is prohibitively expensive, cumbersome, complex, and subject to stringent environmental requirements, maintenance difficulties, and long repair cycles. Therefore, finding an accurate and efficient method to investigate the high-frequency induction brazing process is crucial for precisely understanding the distribution patterns of the welding temperature and stress-strain fields. This theoretical guidance is of significant practical importance for accurately controlling welding quality and performance. Summary of the Invention

[0004] The purpose of this invention is to provide a method for simulating and optimizing process parameters of high-frequency induction brazing, so as to overcome the shortcomings of existing high-frequency induction brazing process research difficulties.

[0005] The technical solution adopted by this invention to solve the above-mentioned technical problems is: a method for simulating and optimizing process parameters of high-frequency induction brazing, comprising the following steps: Step 1: Establish the finite element model of the parts to be welded; Step 2: Input the relevant data of the finite element model of the part to be welded into the Sysweld software, and simulate the heating method of high frequency induction brazing through the heat treatment module of the Sysweld software; Step 3: Select multiple different simulated temperatures, all of which are between the melting point of the brazing filler metal and the melting point of the parts to be welded. Step 4: Input multiple simulated temperatures into the Sysweld software for calculation to obtain welding stress cloud diagrams corresponding to multiple simulated temperatures, and then obtain the maximum welding stress value corresponding to each of the multiple simulated temperatures. Step 5: Compare the multiple maximum welding stress values ​​obtained in Step 4, and take the one with the smallest value as the optimal welding stress value. Then, take the simulated temperature corresponding to the optimal welding stress value as the optimal simulated temperature. Step 6: Perform high-frequency induction brazing experiments on the parts to be welded, ensuring that the welding temperature is the optimal simulated temperature. During the experiment, test the welding stress and obtain the maximum test stress value. Step 7: Compare the optimal welding stress value with the maximum test stress value. When both meet the error requirements, use the optimal simulated temperature as the process parameter for high-frequency induction brazing. When they do not meet the error requirements, reselect the simulated temperature and repeat steps 3 to 7 until the optimal welding stress value and the maximum test stress value meet the error requirements.

[0006] Preferably, in step three, at least three different simulated temperatures are selected.

[0007] Preferably, in step seven, the error between the optimal welding stress value and the maximum test stress value is required to be no more than 5%.

[0008] According to the above technical solution, the beneficial effects of the present invention are: This invention provides...

[0009] This invention can quickly and efficiently calculate the stress and strain fields corresponding to a given temperature under certain conditions. When compared with the results reported from the factory, the error between the simulated and theoretical values ​​is within 5%, meeting the error criteria and demonstrating the accuracy of the numerical simulation results. The method of this invention can effectively reduce losses and time costs in actual high-frequency induction brazing operations. Furthermore, numerical simulation allows for the modification of different welding parameters, analysis of the optimal welding process, and experimental verification. Experimental results verify the correctness and reliability of the numerical simulation calculations, providing theoretical guidance and technical support for the precise control of welding process parameters in high-frequency induction brazing. Attached Figure Description

[0010] Figure 1 A schematic diagram of the finite element model of an aircraft chassis; Figure 2 Stress cloud diagram of an aircraft chassis at 580℃ during welding; Figure 3 Stress cloud diagram of an aircraft chassis at 590℃ during welding; Figure 4 This is a welding stress cloud diagram of an aircraft chassis at 595℃. Detailed Implementation

[0011] A method for simulating and optimizing process parameters in high-frequency induction brazing includes the following steps: Step 1: Establish the finite element model of the part to be welded.

[0012] Step 2: Input the relevant data of the finite element model of the part to be welded into the Sysweld software, and simulate the heating method of high frequency induction brazing through the heat treatment module of the Sysweld software.

[0013] Step 3: Select at least three different simulated temperatures, all of which are between the melting point of the brazing filler metal and the melting point of the parts to be soldered.

[0014] Step 4: Input multiple simulated temperatures into the Sysweld software for calculation to obtain welding stress cloud diagrams corresponding to multiple simulated temperatures, and then obtain the maximum welding stress value corresponding to each of the multiple simulated temperatures.

[0015] Step 5: Compare the multiple maximum welding stress values ​​obtained in Step 4, and take the one with the smallest value as the optimal welding stress value. Then, take the simulated temperature corresponding to the optimal welding stress value as the optimal simulated temperature.

[0016] Step 6: Perform high-frequency induction brazing experiments on the parts to be welded, ensuring that the welding temperature is the optimal simulated temperature. During the experiment, test the welding stress and obtain the maximum test stress value.

[0017] Step 7: Compare the optimal welding stress value with the maximum test stress value. When both meet the error requirement, use the optimal simulated temperature as the process parameter for high-frequency induction brazing. When they do not meet the error requirement, reselect the simulated temperature and repeat steps 3 to 7 until the optimal welding stress value and the maximum test stress value meet the error requirement, which shall not exceed 5%.

[0018] Taking an aircraft chassis as an example, the specific implementation is as follows: Step 1: Establish a finite element model of the aircraft chassis, such as... Figure 1 As shown.

[0019] Step 2: Input the relevant data of the finite element model of the aircraft chassis into the Sysweld software, and simulate the heating method of high-frequency induction brazing using the heat treatment module of Sysweld software. Because it is difficult to implement the heat source loading in the welding module of Sysweld software, the heat treatment module is selected to simulate the working environment of the high-frequency induction brazing furnace.

[0020] Step 3: The melting point of the aircraft chassis is 656℃, and the melting point of the brazing filler metal is 550℃. Therefore, 580℃, 590℃, and 595℃ are selected as simulation temperatures between 550℃ and 656℃.

[0021] Step 4: Input 580℃, 590℃, and 595℃ into the Sysweld software for calculation to obtain welding stress cloud diagrams corresponding to the three simulated temperatures. The welding stress cloud diagram for 580℃ is shown below. Figure 2 As shown, the welding stress cloud diagram at 590℃ is as follows: Figure 3 As shown, the welding stress cloud diagram at 595℃ is as follows. Figure 4 As shown.

[0022] according to Figure 2 The maximum welding stress at 580℃ can be obtained as 205.073 MPa, according to... Figure 3 The maximum welding stress at 590℃ can be obtained as 192.805 MPa, according to... Figure 4 The maximum welding stress at 595℃ is 194.426 MPa.

[0023] Step 5: Compare the three maximum welding stress values ​​obtained in Step 4, and take the smallest value of 192.805 MPa as the optimal welding stress value. Therefore, take the corresponding 590℃ as the optimal simulation temperature.

[0024] Step 6: A high-frequency induction brazing experiment was conducted on the aircraft chassis at a welding temperature of 590℃. During the experiment, the welding stress was tested, and the maximum test stress value was 201.56MPa.

[0025] Step 7: Compare the optimal welding stress value of 192.805 MPa with the maximum test stress value of 201.56 MPa. The error between the two is 4.34%, which is less than the 5% error requirement. Therefore, there is no need to reselect the simulation temperature. The optimal simulation temperature of 590℃ can be directly used as the process parameter for high-frequency induction brazing, thereby realizing the simulation optimization of the process parameters for high-frequency induction brazing.

Claims

1. A method for simulating and optimizing process parameters in high-frequency induction brazing, characterized in that, Includes the following steps: Step 1: Establish the finite element model of the parts to be welded; Step 2: Input the relevant data of the finite element model of the part to be welded into the Sysweld software, and simulate the heating method of high frequency induction brazing through the heat treatment module of the Sysweld software; Step 3: Select multiple different simulated temperatures, all of which are between the melting point of the brazing filler metal and the melting point of the parts to be welded. Step 4: Input multiple simulated temperatures into the Sysweld software for calculation to obtain welding stress cloud diagrams corresponding to multiple simulated temperatures, and then obtain the maximum welding stress value corresponding to each of the multiple simulated temperatures. Step 5: Compare the multiple maximum welding stress values ​​obtained in Step 4, and take the one with the smallest value as the optimal welding stress value. Then, take the simulated temperature corresponding to the optimal welding stress value as the optimal simulated temperature. Step 6: Perform high-frequency induction brazing experiments on the parts to be welded, ensuring that the welding temperature is the optimal simulated temperature. During the experiment, test the welding stress and obtain the maximum test stress value. Step 7: Compare the optimal welding stress value with the maximum test stress value. When both meet the error requirements, use the optimal simulated temperature as the process parameter for high-frequency induction brazing. When they do not meet the error requirements, reselect the simulated temperature and repeat steps 3 to 7 until the optimal welding stress value and the maximum test stress value meet the error requirements.

2. The method for simulating and optimizing process parameters of high-frequency induction brazing according to claim 1, characterized in that: In step three, at least three different simulated temperatures are selected.

3. The method for simulating and optimizing process parameters of high-frequency induction brazing according to claim 1, characterized in that: In step seven, the error between the optimal welding stress value and the maximum test stress value must not exceed 5%.

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