金属加工（热加工）Issue(11)：68-74,7.
TIG焊接下AISI 4130车架钢管有限元分析与多尺度疲劳寿命评估
Finite element analysis and multi-scale fatigue life evaluation of AISI 4130 frame steel pipe under TIG welding
摘要
Abstract
This study systematically investigates the mechanical properties and fatigue characteristics of AISI 4130 chassis steel tubes under TIG welding processes,focusing on the U20 roll cage welding right-angle butt joint specimens from the China SAE Baja Competition.A thermomechanical coupled finite element model based on the Goldak double ellipsoid heat source was constructed to dynamically simulate the welding temperature field and residual stress field using ANSYS Workbench.A multiaxial fatigue life evaluation system integrating the mean stress-corrected Morrow model and the E-N curve method was established via nCode Design Life.Innovatively adopting response surface methodology to optimize welding parameters,a three-factor three-level orthogonal experiment revealed that optimal weld quality is achieved at welding speed of 3mm/s,welding duration of 20s,and power density of 40W/mm2.Under these conditions,the weld penetration reached 3.2mm,with an 18％improvement in weld width uniformity,a residual stress peak reduction to 285MPa,and a maximum deformation of 0.08mm,representing a 23％enhancement in forming quality compared to conventional parameters.Microstructural analysis indicated refined grain sizes(12～15μm)in the weld zone and a 37％reduction in hardness gradient within the heat-affected zone.Multibody dynamics-based load spectrum analysis demonstrated spatially graded fatigue life distributions:the minimum fatigue life of 7.37 × 107 cycles occurred at 15mm from the loading point,while the maximum fatigue life of 7.31 × 108 cycles was recorded at 30mm from the loading point,compliant with SAE J 1099 standards.Experimental validation confirmed a prediction error of less than 9.2％for the finite element model.The study establishes a quantitative mapping relationship among welding parameters,microstructural properties,and fatigue life,providing a damage tolerance design-based framework for selecting process windows in high-strength steel racing chassis optimization.关键词
AISI 4130/TIG焊接/有限元分析/疲劳寿命/车架钢管Key words
AISI 4130/TIG welding/finite element analysis/fatigue life/frame steel tubing引用本文复制引用
权建毅,陈陆陵,沈锋,解印琦,赵博洋,宋勇,白晶晶..TIG焊接下AISI 4130车架钢管有限元分析与多尺度疲劳寿命评估[J].金属加工（热加工）,2025,(11):68-74,7.基金项目
山西省基础研究计划面上项目(202403021221149). （202403021221149）
