汽车驱动桥壳焊接变形及焊接残余应力有限元仿真分析

汽车驱动桥壳焊接过程中复杂的温度场与焊接残余应力分布使桥壳产生了较大的焊接变形，利用CATIA建立桥壳三维模型， 使用Simufact Welding软件对其焊接温度场和焊接残余应力及焊接变形进行模拟分析，研究了装夹条件对桥壳焊接变形及焊接残余应力的影响.结果表明:桥壳焊接变形以桥壳两端向焊缝方向收缩翘曲变形为主，最大值为11.63mm，桥壳焊缝的焊接残余应力以桥壳轴向方向的拉应力为主.在桥壳焊接冷却阶段，延长夹具对桥壳的约束控制时间(600s)可以有效地减少桥壳的焊接变形及焊接残余应力，与桥壳焊接的全自由冷却(保持夹具对桥壳的冷却控制时间30s)相比，桥壳焊接变形减小了20%~26%.

Finite Element Simulation Analysis of Welding Deformation and Welding Residual Stress of Automobile Drive Axle Housing

The complex temperature field and welding residual stress distribution in the welding process of automobile drive axle housing make the axle housing produce large welding deformation. A three-dimensional model of axle housing is established by CATIA， and the welding temperature field， welding residual stress and welding deformation are simulated and analyzed by Simufact Welding software. The influence of clamping conditions on the welding deformation and residual stress of axle housing is studied. The results show that the welding deformation of axle housing is mainly caused by the shrinkage and warpage of both ends of the axle housing in the direction of the welding seam， and the maximum value is 11.63mm. The residual stress of axle housing welding is mainly the axial tensile stress of the axle housing. In the cooling stage of axle housing welding， prolonging the constraint control time(600s)of the fixture on the axle housing can effectively reduce the welding deformation and residual stress of axle housing. Compared with the full free cooling(keeping the cooling control time of the fixture on axle housing for 30s)， the welding deformation of axle housing is reduced by 20%~26%.