Welding distortion control of automobile engine stator by finite element method

Abstract

In this paper, a thermal elastic-plastic finite element method (FEM) is used to simulate the plasma welding process in order to predict the welding distortion of automobile stator iron core. Six spatial symmetrical welding torches are adopted in the welding process so as to make the iron core rings welded firmly and the distortion symmetric. The effect of rigid clamp on actual welding process is replaced by the contact function between rigid body and deformation element in the MSC software, MARC. The welding process restrained by clamp and deformation analysis after the removal of clamp was successfully simulated. The predictions show good agreement with the test results when the rigid clamps are taken into account in the welding simulation, which satisfies the design requirement for manufacture.

Keywords

SPCC automobile engine stator / rigid clamp / numerical simulation / welding distortion

References

[1] Radaj D. Heat Effects of Welding: Temperature Field, Residual Stress, Distortion. New York: Springer-Verlag, 1992, 8-20

[2] Deng D, Murakawa H, Liang W. Numerical simulation of welding distortion in large structures. Surface & Coatings Technology, 2007, 196: 4613-4627

[3] Goldak J, Chakravarti A, Bibby M. A new finite model for welding heat source. Metallurgia Transactions, 1984, 15(2): 299-305

[4] Keanini R G. Simulation of weld pool flow and capillary interface shapes associated with the plasma arc welding process. Finite Elements in Analysis and Design, 1993, 15(1): 83-92

[5] Keanini R G, Rubinsky B. Three-dimensional simulation of the plasma arc welding process. International Journal of Heat and Mass Transfer, 1993, 36(13): 3283-3298

[6] Tam S C, Lindgren L-E, Yang L J. Computer simulation of temperature fields in mechanized plasma-arc welding. Journal of Mechanical Working Technology, 1989, 19(1): 23-33

RIGHTS & PERMISSIONS

2014 Higher Education Press and Springer-Verlag Berlin Heidelberg