考虑温变效应的搅拌工具磨损有限元分析

根据搅拌摩擦焊接过程材料热物参数温变特性，基于库伦摩擦做功和经典Archard磨损理论，分别建立了6061铝合金薄板搅拌摩擦焊热源修正模型和搅拌工具H13模具钢磨损模型，并嵌入到Deform有限元仿真软件中，模拟了有无考虑温变下搅拌工具的磨损量分布形貌和磨损规律. 结果表明，两种情况下搅拌工具磨损量分布形貌基本一致，温变效应使得搅拌工具和接头材料间力热作用加剧，在焊接过程中，搅拌工具的磨损系数对温变效应的敏感性要大于材料硬度的变化. 考虑温变效应的搅拌工具磨损模型能更加反映其磨损变化规律，具有较高的磨损预测精度.

Finite element analysis on wear of stirring tool considering temperature effect

According to temperature-depending characteristics of thermo-physical parameters of the welded material during friction stir welding (FSW) process, the modified heat source model of 6061 aluminum alloy sheet was established based on the work done by Coulomb friction, a modified Archard wear model of H13 die steel tool employed in the welding of 6061 aluminum alloy was proposed considering temperature effect. The above two models were embedded into the finite element model. The wear behavior and morphology of H13 die steel tool during plunging into the welded joint and traversing along the welded joint was simulated and analyzed with and without considering the temperature effect. The results showed that the wear behavior and morphology of H13 die steel tool was nearly consistent under the two kinds of conditions. The interaction between stirring tool and base material was intensified under temperature-depending effect, and the wear coefficient of the stirring tool in the welding process was more sensitive to the temperature effect than the change of the material hardness. Thus, it was concluded that the wear model of stirring tool considering the temperature effect had higher accuracy of stirring tool wear prediction.