考虑熔池与小孔的耦合作用,建立了穿孔等离子弧焊接三维瞬态熔池流体流动和传热过程的数学模型.采用流体体积函数法追踪小孔的形状与尺寸,利用焓-孔隙度法处理凝固熔化过程中的相变潜热以及动量损耗问题.针对穿孔等离子弧焊接的工艺特点,建立了随小孔深度动态调整的组合式体积热源模式.对8 mm板厚的不锈钢工件进行了穿孔焊接工艺实验和数值模拟,获得了等离子弧焊接过程中熔池出现、小孔形成、流场与温度场演变、工件熔透与穿孔等动态过程的基础数据,展示了小孔穿孔前后熔池流体流动规律.工件背面小孔形状尺寸以及焊缝横断面的数值模拟结果与实验测试结果基本吻合.
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