基于二次多项式新本构模型的铝合金搅拌摩擦焊板材成形极限研究

doi:10.11900/0412.1961.2016.00178

金属学报

2017, Vol. 53

Issue (1): 114-122 DOI: 10.11900/0412.1961.2016.00178

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基于二次多项式新本构模型的铝合金搅拌摩擦焊板材成形极限研究

初冠南¹,林艳丽¹(

),宋伟宁²,张林¹

1 哈尔滨工业大学(威海) 威海 2642092 威海北洋电气集团股份有限公司威海 264209

Forming Limit of FSW Aluminum Alloy Blank Based on a New Constitutive Model

Guannan CHU¹,Yanli LIN¹(

),Weining SONG²,Lin ZHANG¹

1 School of Materials Science & Engineering, Harbin Institute of Technology at Weihai, Weihai 264209, China;
2 Weihai Northern Electric Group Company Limited, Weihai 264209, China

引用本文:

初冠南,林艳丽,宋伟宁,张林. 基于二次多项式新本构模型的铝合金搅拌摩擦焊板材成形极限研究[J]. 金属学报, 2017, 53(1): 114-122.
Guannan CHU, Yanli LIN, Weining SONG, Lin ZHANG. Forming Limit of FSW Aluminum Alloy Blank Based on a New Constitutive Model[J]. Acta Metall Sin, 2017, 53(1): 114-122.

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摘要:

针对铝合金焊缝性能低于母材、现有成形极限分析方法不适宜分析铝合金搅拌摩擦焊板材成形极限的现状,提出了一种基于二次多项式新本构模型的铝合金拼焊板成形极限理论模型。核心思想为利用材料自身的性能差异替代经典M-K理论模型的沟槽假设。针对铝合金硬化指数低、幂指数回归精度差的问题,将二次多项式新本构模型应用于M-K理论模型,最终建立了适合于铝合金搅拌摩擦焊拼焊板的成形极限理论预测模型。对铝合金搅拌摩擦焊板材进行了成形极限实验,并通过XJTUDIC三维数字散斑应变变形测量系统实时测量变形过程中的应变值,得到了铝合金搅拌摩擦焊拼焊板的实验成形极限图。最后对实验结果和理论分析结果进行了对比。相比传统的幂指数本构模型,二次多项式对应力-应变曲线的回归,无论在初试屈服阶段或后期变形阶段均有很好的吻合精度。幂指数最大拟合误差超过12%,而二次多项式的拟合误差小于1%,二次多项式回归模型能很好地拟合铝合金搅拌摩擦焊接接头的应力-应变关系;采用二次多项式本构关系的理论模型能很好地预测铝合金搅拌摩擦焊板材的成形极限,第一主应变的预测误差小于0.01;而幂指数理论模型则导致平面应变状态下的极限应变预测结果明显不准,在相同应变路径下第一主应变的预测误差达0.14。

关键词 ：铝合金, 搅拌摩擦焊, 成形极限, 应力-应变曲线, M-K模型

Abstract：

Automobile lightweight can effectively save fuel consumption and reduce CO₂ emissions. Aluminum and its alloys are desirable for the automotive industry due to their excellent high-strength to weight ratio. However, due to the introduction of the welding seam, it has brought new changes to the forming process, especially to the forming limit. To establish a reasonable forming limit curve (FLC) analysis method of friction stir welding (FSW) aluminum alloy blank, a new theoretical model was proposed based on the new second order function constitutive model. The main idea is using the differences in mechanical property between the welding and heat affected zone substitution for the hypothesis of geometry groove in the classic M-K theoretical model. The new second order function constitutive model was applied to M-K theoretical model. Eventually, a new FLC theoretical model for FSW aluminum alloy blank was established. Such theoretical model also overcomes the low strain hardening exponent of aluminum alloy material, which leads to a poor regression accuracy by power-exponent function model. The forming limit test for FSW aluminum alloy blank was performed, and the real-time strain was measured by three-dimensional digital speckle strain measurement system (XJTUDIC). Finally, the results of experiments and the theoretical analysis are compared. Compared with the traditional power law, the regression result of the new second order function constitutive model on the stress-strain curve no matter in the initial yield stage or in late deformation stage has a good fitting precision. The maximum fitting error of the power law on the stress-strain curve is more than 12%, but the fitting error of the new second order function constitutive model is less than 1%. The theoretical prediction based on the new second order function constitutive model is significantly better than the theoretical predictions based on power law in predicting the forming limit of FSW aluminum alloy blank. The prediction error of the first principal strain based on the new second order function constitutive model is less than 0.01. While the maximum prediction error of the first principal strain based on the power law is 0.14.

Key words： aluminum alloy friction stir welding forming limit stress-strain curve M-K model

收稿日期: 2016-05-10

基金资助:资助项目国家自然科学基金项目Nos.51405102和51475121,中国博士后科学基金项目No.2015M570286,中央高校基本科研业务费专项资金项目No.HIT.NSRIF.2016093及哈尔滨工业大学(威海)校科学研究基金项目No.HIT(WH)201414

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https://www.ams.org.cn/CN/10.11900/0412.1961.2016.00178 或 https://www.ams.org.cn/CN/Y2017/V53/I1/114

图1 M-K理论模型

图2 改进后M-K模型的具体迭代计算算法

图3 焊接后板材照片

图4 试样拉伸示意图

图5 实验后试样及应变分布

图6 300 ℃退火后接头焊核与母材的的组织形貌

表1 二次多项式拟合时采用的实验数据点

表2 二次多项式拟合所得系数

图7 流动应力-应变回归曲线

图8 理论预测结果与实验结果对比

图9 理论预测结果误差分析

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