Simulation of nonuniform heating induced by alternating-current rail flash butt welding at the end face

被引:0
作者
Wang, Xiao [1 ]
Chen, Hui [1 ]
Zhu, Zongtao [1 ]
Hao, Meiqi [1 ]
Tan, Hongtao [2 ]
Pei, Yuhu [3 ]
Lv, Qibing [1 ]
机构
[1] Southwest Jiaotong Univ, Sch Mat Sci & Engn, Chengdu, Sichuan, Peoples R China
[2] Chengdu Aigre Technol Co Ltd, Chengdu 611743, Sichuan, Peoples R China
[3] China Tiesiju Civil Grp, Eighth Construct Co Ltd, Hefei, Anhui, Peoples R China
关键词
Rail flash butt welding; Numerical simulation; End face heat generation; Electric-magnetic-thermal coupling; NUMERICAL-SIMULATION; MECHANICAL-PROPERTIES; FRACTURE MECHANISM; RESIDUAL-STRESS; MICROSTRUCTURE; STEEL; JOINT;
D O I
10.1007/s40194-024-01821-6
中图分类号
TF [冶金工业];
学科分类号
0806 ;
摘要
Nonuniform temperature field upsetting is prone to oxide inclusions, and the temperature field of rail flash butt welding (FBW) is primarily formed because of the Joule heat generated by the end-face current. The current distribution at the end face largely determines the heat distribution; thus, the current distribution and heat production at the end face of an alternating-current (AC) FBW must be investigated. This study combined finite element simulation and experimental validation to establish an AC rail FBW electric-magnetic-thermal coupling model to explore the influence of current parameters, end-face temperature, and feed mode on the distribution of the end-face current. The results show that a reduction in the welding current, current frequency, and time in low- and medium-temperature stages can improve the uniformity of the temperature field. The electrode clamping method determines the shape of the temperature field, whereas the proposed hybrid clamping method is the most conducive to uniform heat generation at the end face. Moreover, electrode clamping at 210 mm near the end face yielded uniform temperature fields. The experimental validation results were consistent with the calculated results, indicating that the proposed model is reasonable and reliable. In practical welding operations, it is advisable to optimize current and frequency to achieve an end face temperature > 1000 degrees C swiftly. This study provides a direction for enhancing the uniformity of the temperature field and improving the expulsion capability of impurities during the upsetting process, thereby optimizing the flash butt welding process for rails.
引用
收藏
页码:2735 / 2749
页数:15
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