Spot-Ring Laser Heat Source Modeling for Accurate Welding Simulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a lack of a suitable heat source model for spot-ring laser welding, particularly for ring-core adjustable lasers, which hinders the simulation of energy distribution and welding characteristics.
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, and implemented through finite element simulation using specific software and programming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional single-spot laser heat source model is used, then the model establishment is simple, but it cannot accurately represent spot-ring laser welding heat source energy distribution
Solution Approach 1:
The spot-ring laser heat source is segmented into two independent components: a central spot laser heat source (volume heat source) and an annular ring laser heat source (surface heat source). Each component has its own heat flux density function and can be independently controlled through parameters such as power distribution coefficient α, spot radius rv, and ring radius range [r1, r2]. This segmentation allows accurate representation of the complex energy distribution while maintaining manageable model structure.
2Measurement precision
If spot-ring laser welding heat source model is established, then energy distribution simulation accuracy is improved, but the model establishment complexity increases
Solution Approach 1:
Different regions of the heat source are assigned different mathematical models and physical characteristics. The central spot region uses a volume heat source model with Gaussian-like distribution, while the annular ring region uses a surface heat source model with concentrated distribution at radius rs. This local quality differentiation allows each region to be modeled with appropriate complexity, improving overall simulation accuracy without uniformly increasing model complexity throughout.
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 precise control of energy distribution and welding parameters.
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
AI summary
The invention relates to a method, system, and medium for establishing a heat source model of spot-ring laser welding. The spot-ring laser consists of a central spot laser forming a volumetric heat source and a ring laser forming an annular surface heat source. The spot laser enables a high aspect ratio weld, while the ring laser provides auxiliary heating and controlled cooling of the material. The method allows the laser power ratio between the spot and ring lasers to be adjusted at any proportion, enables independent control of their defocus amounts, and uses parameters such as spot and ring diameters to effectively characterize heat flux density distribution. This model supports accurate simulation of temperature, stress, and deformation fields for spot-ring laser welding and is applicable to finite element simulations of linear and swing welding paths.