赵小健

摘  要：针对焊接精密钢球强度、精度和表面质量要求，设计内凹半球铜电极并开展了中频点焊焊接试验，获得焊接缺陷情况。然后利用ansys的电流仿真功能，获得了点焊过程中电流分布规律，确定了产生球面局部缺陷的原因，进而优化仿真参数，获得电流分布情况，确定优化参数，指导了焊接电极优化，最终优化上电极并进行焊接试验，获得各项指标合格的理想样件。

关键词：中频点焊  焊接试验  电流分布  焊接电极

中图分类号：TG115                           文献标识码：A文章编号：1674-098X（2021）04（b）-0112-03

Research on welding technology of precision steel ball based on finite element method

ZHAO Xiaojian

（Institute of physical and Chemical Engineering of nuclear industry， Tianjin， 300180 China）

Abstract：According to the requirements of strength，precision and surface quality of welding precision steel ball，the concave copper electrode was designed and intermediate frequency spot welding test was carried out to obtain the welding defects. Then，by using the current simulation function of ansys，the current distribution law in the process of spot welding was obtained，and the cause of the spherical local defects was determined，then the simulation parameters were optimized，the current distribution was obtained，and the optimized parameters were determined，the welding electrode was optimized，and finally the upper electrode was optimized and the welding test was carried out，and the ideal sample with qualified indexes was obtained.

key words：Intermediate frequency spot welding，Welding test; Current distribution; Welding electrode

機械加工行业中常采用精密车削、磨削和研磨等手段加工球形轴结构件，成本较高，而采用焊接精密钢球的方法获得高精度球形轴结构件，成本较低。为探索焊接精密钢球技术，国内曾采用纯银电极进行电阻点焊试验，获得焊接样件，但球面因局部过热产生氧化变色甚至退火软化而无法使用;曾采用低熔点材料设计电极，焊接样件能满足扭矩需求[1]，但电极因先于钢球熔化而难以重复使用。目前关于电流等参数对焊接质量的影响研究很多[2-3]，通过有限元方法取得了较大进展，尤其是王士军等应用ansys对焊接电流分布进行研究[4]，周婷等对平面接触电阻点焊过程进行研究[5]。以上均对焊接精密钢球研究很有帮助。

本研究选用中频点焊技术，对标准紫铜电极进行改制，设计环状接触面[6]，然后进行点焊钢球试验，以获得球形轴结构件表面缺陷情况及其分布规律;然后利用ansys软件的电流仿真功能模拟焊接过程电流分布，指导焊接工艺优化。……