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利用ANSYS n Code Designlife建立了搅拌摩擦焊(FSW)过程搅拌头的疲劳模型。结合FSW过程中实测的搅拌头作用力载荷谱以及搅拌头扭矩公式,获得了搅拌头的作用力与疲劳寿命两者之间的关系,着重研究了前进阻力平均值与其周期性载荷幅值的大小对疲劳寿命的影响。模拟结果表明,前进阻力及其周期性载荷是造成搅拌头疲劳失效的主要因素,而侧向力与扭矩是次要因素;下压力有利于提高搅拌头的疲劳寿命。搅拌头的疲劳寿命随着前进阻力与前进阻力幅值的增加而减小。焊接参数的改变对搅拌头疲劳寿命的影响较大,但无明显规律。在FSW过程中,下压力平均值与前进阻力平均值的比值的增加有利于降低前进阻力周期性载荷的幅值,进而提高搅拌头的疲劳寿命。对于13mm厚的2024铝合金,当下压力平均值与前进阻力平均值的比值大于2时,搅拌头的疲劳寿命大幅度提高。
The fatigue model of FSW stirrer was established by using ANSYS n Code Designlife. According to the measured load spectrum of the stirrer head and the formula of the torque of the stirrer head during the FSW process, the relationship between the force and the fatigue life of the stirrer head was obtained. The relationship between the mean value of the forward resistance and the amplitude of the periodic load Impact on fatigue life. The simulation results show that the forward resistance and its periodic load are the main factors that cause the fatigue failure of the stirring head, while the lateral force and torque are the secondary factors. The lower pressure helps to improve the fatigue life of the stirring head. The fatigue life of the mixing head decreases with the increase of the forward resistance and the forward resistance. Changes in welding parameters of the fatigue life of stirrer greater impact, but no obvious law. During the FSW process, the increase of the ratio of the average value of the lower pressure to the average value of the forward resistance helps to reduce the amplitude of the periodic load of the forward resistance, thereby increasing the fatigue life of the stirring head. For 13mm thick 2024 aluminum alloy, the current fatigue life of the mixing head is greatly increased when the ratio of the average current pressure to the average forward resistance is greater than 2.