汽车钢制车轮组合焊接的残余应力场研究

doi:10.3901/JME.2024.22.291

机械工程学报 ›› 2024, Vol. 60 ›› Issue (22): 291-301.doi: 10.3901/JME.2024.22.291

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汽车钢制车轮组合焊接的残余应力场研究

代金垚^1,2, 刘献栋^1,2, 单颖春^1,2, 姜二³

1. 北京航空航天大学交通科学与工程学院北京 100191;
2. 北京航空航天大学新能源汽车高效动力传动与系统控制北京市重点实验室北京 100191;
3. 兴民智通有限公司烟台 265700

收稿日期:2024-02-11 修回日期:2024-05-12 出版日期:2024-11-20 发布日期:2025-01-02
作者简介:代金垚,男,1998年出生。主要研究方向为汽车结构焊接分析、强度与及疲劳。E-mail:ZY1913109@buaa.edu.cn;刘献栋(通信作者),男,1966年出生,博士,教授,博士研究生导师。主要研究方向为汽车结构强度与疲劳、汽车振动与噪声控制。E-mail:liuxiandong@buaa.edu.cn
基金资助:
国家自然科学基金资助项目(51875025)。

Research on the Residual Stress Field of Combined Welding of Automotive Steel Wheel

DAI Jinyao^1,2, LIU Xiandong^1,2, SHAN Yingchun^1,2, JIANG Er³

1. School of Transportation Science and Engineering, Beihang University, Beijing 100191;
2. Beijing Key Laboratory for High-efficient Power Transmission and System Control of New Energy Resource Vehicle, Beihang University, Beijing 100191;
3. Xingmin Intelligent Transportation System Co., Ltd., Yantai 265700

Received:2024-02-11 Revised:2024-05-12 Online:2024-11-20 Published:2025-01-02
About author:10.3901/JME.2024.22.291

摘要/Abstract

摘要： 车轮是汽车中承受载荷最为恶劣的部件之一，其结构安全性直接影响着汽车性行车安全，且由车轮断裂产生的交通事故时有发生。商用车钢制车轮是由预先制成的轮辐与轮辋经过盈装配、焊接而成，其焊趾部位是车轮上最易发生疲劳开裂的部位，该部位的总应力是焊接残余应力与工作应力的叠加。车轮的构型复杂且应力分布不均匀，很难通过试验方法测量车轮组合焊接残余应力分布，但为准确预测车轮应力进而进行准确的轻量化设计，需要精确预测焊接残余应力分布。为此，首先构建考虑焊接过程中金属相变的车轮热-力-相变场耦合焊接仿真模型，通过对比试验与仿真中熔池形状初步验证热源模型热量输入的准确性；接着，进一步对比分析仿真所得温度场与试验所得温度场，以验证仿真所得温度场的准确性；之后，通过盲孔法测量焊接残余应力验证了仿真方法所得残余应力场具有较高准确性，并且还发现轮辋焊趾处残余应力沿周向呈周期分布，轮辋焊趾在正对通风孔处焊接残余应力小于正对通风孔间辐板处焊接残余应力，过盈装配对轮辋焊趾处焊接残余应力无明显影响。所进行的汽车钢制车轮组合焊接残余应力场研究，有助于获得车轮在考虑焊接残余应力下的真实应力分布，进而对车轮进行更为有效的轻量化设计。

关键词: 汽车钢制车轮, 复合热源模型, 车轮组合焊接, 焊接残余应力

Abstract: The wheel is one of the most severely loaded parts in a vehicle. The structural safety of wheel is vital for the safety of automobile driving, and the traffic accidents caused by broken wheel occur from time to time. The steel wheel in the commercial vehicle is usually made of prefabricated spoke and rim that are assembled and welded. The welding toe is the part most prone to fatigue cracking on the wheel. The total stress of this part is the superposition of welding residual stress and working stress. Since the configuration of the wheel is complicated and the stress distribution is uneven, it is difficult to measure the overall welding residual stress of the wheel through experimental methods. In order to accurately predict the wheel stress and carry out accurate lightweight design, it is necessary to accurately predict the welding residual stress distribution. Aiming at this problem, a thermal-mechanical-phase field coupling simulation model of steel wheel considering the phase transformation of the metal during the welding process is established. And the accuracy of heat input of the heat source model is verified through comparing the shape of the molten pool of simulation and experiment. Then the temperature filed from the simulation and experiment is compared to verify the correctness of simulation model. The welding residual stress measured by the blind hole method indicates that the residual stress field obtained by the simulation method has high accuracy. It is also found that the residual stress at the weld toe is distributed periodically along the circumferential direction, and the welding residual stress of weld toe opposite vent hole is smaller than that opposite wheel disk. The interference fit has no obvious effect on the welding residual stress at the welding toe of the rim. The research on the residual stress field of the combined welding of automotive steel wheel in this paper is helpful to obtain the real stress distribution of the wheel under the consideration of welding residual stress, and plays a vital role in the lightweight of the wheels.

Key words: automotive steel wheel, combined heat source model, combined welding of wheel, welding residual stress

中图分类号:

TG156

代金垚, 刘献栋, 单颖春, 姜二. 汽车钢制车轮组合焊接的残余应力场研究[J]. 机械工程学报, 2024, 60(22): 291-301.

DAI Jinyao, LIU Xiandong, SHAN Yingchun, JIANG Er. Research on the Residual Stress Field of Combined Welding of Automotive Steel Wheel[J]. Journal of Mechanical Engineering, 2024, 60(22): 291-301.

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汽车钢制车轮组合焊接的残余应力场研究

Research on the Residual Stress Field of Combined Welding of Automotive Steel Wheel

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