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为减小梁类件焊后变形,通过施加反变形量来控制焊接变形。以某车型横梁为例,首先分析未采取反向变形约束状态下横梁的焊接变形,得出横梁在自由状态下的焊接变形规律及数值,并进行实物验证;然后预设了5种反向变形约束方案,分别进行模拟分析,并通过数值模拟寻优,确定出最佳反变形量施加的位置和量级。结合分析结果,以试制的方式对所提及的算法进行验证,并制作一套柔性焊接工装夹具,在反变形施加位置加紧约束,通过调整夹具上垫片厚度来调节反变形的施加量。通过实物验证,当反变形量为4 mm时,焊后变形量在1 mm以内,与模拟分析结果吻合。该方法可有效控制梁类件的焊后质量。
In order to reduce the beam after welding deformation, through the application of anti-deformation to control the welding deformation. Taking a vehicle type crossbeam as an example, the welding deformation of the beam under the condition of reverse deformation restraint is analyzed first, and the welding deformation law and numerical value of the beam under free state are obtained and verified by physical verification. Then, five kinds of reverse deformation Constraints program, respectively, the simulation analysis, and optimization by numerical simulation to determine the best position and magnitude of anti deformation. According to the results of the analysis, the proposed algorithm is validated in a trial mode, and a set of flexible welding fixture is fabricated to tighten the constraint at the anti-deformation application position. The amount of anti-deformation is adjusted by adjusting the thickness of the gasket on the fixture. Through physical verification, when the amount of anti-deformation is 4 mm, the deformation after welding is within 1 mm, which is in good agreement with the simulation results. The method can effectively control the quality of beam after welding.