Abstract: Aiming at the limitations of insufficient real-time boundary data and inaccurate construction of simulation models in the traditional numerical simulation method for the welding arc,the PyFluent co-simulation technology was utilized to develop a digital twin model of transient Tungsten Inert Gas arc welding(TIG)driven by real-time electrical signal data and the complicated mechanism model.The TIG welding arc twinning mechanism module was developed based on the Magneto Hydrodynamic(MHD)theory.The PyFluent solution strategy was developed to integrate real-time electrical signal data and the twin mechanism module,and the dynamic development rules for arc temperature and current density was acquired in the welding process.The high fidelity of the digital twin model was verified through the comparative analysis of physical and virtual data.The experimental verification showed that the digital twin model test results were consistent with the experiment arc shape;the TIG welding arc digital twin model driven by real-time electrical signal data and mechanism model could realize high-fidelity mapping of transient welding arcs,which presented a new approach for studying the evolutionary behavior of the welding arc.

Key words: tungsten inert gas arc welding, welding arc, digital twin, welding process, numerical simulation

摘要： 针对传统焊接电弧数值模拟方法中存在的边界数据实时性不足和仿真模型构建不准确的问题,采用PyFluent协同仿真技术构建了实时电信号数据和复杂机理模型驱动的瞬变钨极惰性气体保护焊(TIG)焊接电弧数字孪生模型。首先,基于磁流体动力学(MHD)理论,构建TIG焊接电弧孪生机理模块;其次,通过设计PyFluent流程自动化求解策略,融合实时电信号数据与孪生机理模块,获得实时电信号驱动下的焊接过程电弧温度和电流密度动态演变规律;最后,通过物理-孪生数据的对比分析,验证所构建焊接电弧数字孪生模型的高保真性。试验结果表明,孪生机理模型能准确地模拟出焊接电弧的形态特征,实时电信号数据与机理模型驱动的TIG焊接电弧数字孪生模型可实现瞬变焊接电弧的高保真映射,为焊接电弧演变行为研究提供新方法。

关键词: 钨极惰性气体保护焊, 焊接电弧, 数字孪生, 焊接过程, 数值模拟