Spot-Ring Laser Heat Source Modeling for Accurate Welding Simulation
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Solution Overview
Problem
There is a lack of a suitable heat source model for simulating spot-ring laser welding, particularly for ring-core adjustable lasers, which affects the simulation of energy distribution and spatter suppression mechanisms.
Innovation Solution
A method is developed to establish a heat source model for spot-ring laser welding, incorporating spot laser and ring laser components, with control equations and welding path equations to simulate the energy distribution and welding process, using formulas and language code programs to generate data and images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional single-spot laser heat source model is used, then the model structure is simple, but it cannot accurately represent the energy distribution of spot-ring laser welding
Solution Approach 1:
The spot-ring laser heat source is segmented into two independent components: a central spot laser volume heat source and an annular ring laser surface heat source. Each component has its own heat flux density function and parameters, allowing accurate representation of the complex energy distribution while maintaining manageable model structure through modular decomposition.
2Measurement precision
If spot-ring laser welding heat source model is established, then energy distribution simulation accuracy is improved, but model establishment complexity increases
Solution Approach 1:
The model uses adjustable parameters including laser power distribution coefficient α, heat flux concentration coefficients β and γ, effective heating depth H, and spot parameters (r_v, r_s, r_1, r 2) to flexibly represent different spot-ring laser configurations. These parameter changes allow the model to adapt to various welding conditions without requiring structural modifications.
3Extent of automation
If swing welding path is incorporated, then automation and welding quality are improved, but control equation complexity increases
Solution Approach 1:
The model incorporates dynamic swing welding motion by introducing time-dependent coordinates (x 0(t), y 0(t), z 0(t)) that describe the moving heat source position. The welding path equations for circular and linear swing motions provide systematic ways to handle the dynamic complexity while maintaining automated control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method allows for accurate simulation of temperature, stress, and deformation fields in spot-ring laser welding, enabling effective control of laser power ratios and defocus amounts, and is applicable to finite element simulation of linear and swing welding.
Implementation Method 1
spot-ring laser output by a ring-core adjustable laser is in a spot-ring laser beam mode formed by adding an annular light source outside a conventional spot light source. During welding, front-end ring laser in a welding direction preheats a metal material
Implementation Method 2
flux behavior and heat transfer characteristics of a weld pool of a metal material during welding may be simulated through finite element simulation
Data Source
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AI summary
The present invention discloses a method for establishing a heat source model of spot-ring laser welding, a system, and a medium, and belongs to the field of laser welding. Spot-ring laser includes spot laser of a central laser volume heat source and ring laser of an annular laser surface heat source. The former is used to implement a weld with a high aspect ratio for a to-be-welded material, and the latter is used to implement auxiliary heating and slow cooling for the to-be-welded material. Through the method for establishing a heat source model of spot-ring laser welding provided in the present invention, a laser power ratio of the spot laser and the ring laser in a model can be adjusted at any ratio, defocus amounts of the spot laser and the ring laser can be independently controlled, and spot parameters, such as a spot laser spot diameter and a ring laser spot diameter, can be used to effectively express heat flux density distribution. The method for establishing a heat source model provides a strong reference basis for accurately simulating a temperature field, a stress field, and a deformation field of spot-ring laser welding. In combination with regulation of a welding path, the present invention can be widely applied to the field of finite element simulation of linear welding or swing welding with spot-ring laser.