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采用有限元和物理模拟方法,考察了铝合金AA5182电阻点焊过程中电极点蚀对焊接质量的影响。结果表明:当电极尖端点蚀面积增加时,电极与试件界面上的实际接触面积基本不变,而试件与试件界面上的接触面积显著增加,电流密度大大减小,形成熔核的厚度和直径都减小。物理模拟试验所得熔核的形状和尺寸与有限元法预测结果符合很好。物理模拟和数值模拟都表明,点蚀孔直径为5.0mm时,只能形成厚度十分有限的环状熔核。研究揭示:电极尖端点蚀导致被连接试件之间的接触面积增大是其影响焊接质量的主要原因之一。
Using finite element method and physical simulation method, the influence of electrode pitting on the welding quality during AA5182 resistance spot welding process was investigated. The results show that when the area of the electrode tip pitting increases, the actual contact area between the electrode and the specimen remains almost unchanged, while the contact area between the specimen and the specimen increases significantly, the current density is greatly reduced, and the nugget Both thickness and diameter are reduced. The shape and size of the nugget obtained from the physical simulation experiment are in good agreement with the predictions of the finite element method. Both physical simulation and numerical simulation show that when the pitting hole diameter is 5.0 mm, only a very limited thickness of the annular nugget can be formed. The research reveals that the increase of the contact area between the connected test pieces caused by electrode tip pitting is one of the main reasons that affect the welding quality.