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首页> 外文期刊>Journal of Manufacturing Processes >Numerical modelling and experimental validation of the effect of laser beam defocusing on process optimization during fiber laser welding of automotive press-hardened steels
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Numerical modelling and experimental validation of the effect of laser beam defocusing on process optimization during fiber laser welding of automotive press-hardened steels

机译：激光束散焦对汽车压模钢光纤激光焊接过程优化效果的数值建模与实验验证

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摘要

Automated robotic laser welding is commonly used for the joining of thin-gauge sheet metals for automotive applications due to the precision and speed of the welding process. Without proper process optimization, highspeed laser welding for automotive applications is known to have defects such as porosity, weld concavity, and cyclic humping. Several welding parameters can be adjusted to optimize the laser welding process: decreasing the laser power and the welding speed, changing the intensity distribution of the laser on the surface of the substrate, or by changing the type and flow rate of shielding gas used during welding. However, decreasing the laser power and welding speed leads to a loss in productivity which can be costly in large-scale manufacturing endeavors. This study presents the effect of beam defocusing on the weld pool geometry while holding other parameters constant as the welding mode transitions from full penetration or open keyhole mode (OKM) when the beam is fully focused to partial penetration or closed keyhole mode (CKM) as the beam is defocused. It has been shown that by defocusing the laser beam and controlling the weld pool geometry, the welding process can be stabilized to eliminate defects such as severe concavity without decreasing the laser power or slowing down the welding process. A numerical solution is presented that uses three-dimensional (3D) transient finite element (FE) analysis to calculate the temperature fields and predict the molten weld pool geometry in both the full and partial penetration welding modes using a double conical-Gaussian (DCG) volumetric heat source derived from the classical 3D conical-Gaussian (CG) heat source. The model was calibrated using video imaging of the welding process and known experimental data, and it was validated using an extensive experimental study. The results of this work show that the model can be used to predict the molten weld pool geometry that stabilizes the liquid flow in the melt pool during high-speed laser welding whereby allowing faster speeds to be used in the manufacturing of laser-welded components.
机译：由于焊接过程的精度和速度，自动机器人激光焊接通常用于实现汽车应用的薄表板金属。没有适当的过程优化，已知用于汽车应用的高速激光焊接具有诸如孔隙率，焊接凹陷和循环振荡的缺陷。可以调整多个焊接参数以优化激光焊接过程：降低激光功率和焊接速度，改变激光器的强度分布在基板表面上，或通过改变焊接期间使用的屏蔽气体的类型和流速来调节。 。然而，降低激光功率和焊接速度导致生产率的损失，这在大规模制造始终中可能是昂贵的。本研究介绍了束散焦在焊接池几何上的效果，同时将其他参数恒定，因为当光束完全聚焦到部分穿透或闭合锁孔模式（CKM）时，随着焊接模式从完全穿透或打开锁孔模式（OKM）的转换恒定。光束是散焦的。已经表明，通过对激光束进行灰路并控制焊接池几何形状，可以稳定焊接过程以消除诸如严格凹陷的缺陷，而不会降低激光功率或减慢焊接过程。提出了一种使用三维（3D）瞬态有限元（FE）分析来计算温度场并在使用双锥形高斯（DCG）中的全部和部分穿透焊接模式中的熔融焊接池几何形状的数值解决方案。来自古典3D锥形高斯（CG）热源的体积热源。使用焊接过程的视频成像和已知的实验数据进行校准该模型，并使用广泛的实验研究验证。该工作的结果表明，该模型可用于预测熔融焊接池几何形状，其在高速激光焊接期间稳定熔池中的液体流动，从而允许在激光焊接部件的制造中使用更快的速度。

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