本文以煤矿液压支架油缸的使用环境为背景，利用有限元数值模拟分析软件，对圆筒工件内壁涂层感应熔覆工艺的有关参数进行了数值模拟，搭建试验平台进行试验以期获得高质量的铜合金熔覆层。本文的主要研究内容如下所示：

首先，在焦耳热定律和麦克斯韦方程组的数学理论基础上，建立了圆筒工件内壁高频感应熔覆铜合金的有限元数值模拟模型，依据现有的经验试验参数模拟高频感应熔覆过程。有限元数值模拟分析以电磁-热耦合为核心，依次对圆筒内壁感应熔覆铜合金的电磁场、温度场和电磁-热耦合场进行了分析，同时将导磁体引入了分析提高了数值模拟的准确性。

其次，通过对圆筒工件内壁感应熔覆铜合金的数值模拟，研究各工艺参数对圆筒温度分布及达到熔覆温度时间的影响。研究发现，铜合金涂层在感应加热初期温度上升较快，逐步达到温度上升不明显的动态平衡状态，高频感应加热的电流频率、高频感应线圈的外径大小（线圈与熔覆层的间隙）、电源的功率、涂层厚度和高频感应线圈正方形截面边长对感应熔覆加热过程均产生不同的影响。

最后，通过实际的高频感应熔覆试验来验证其数值模拟的准确性。高频感应熔覆试验时用红外测温仪对感应熔覆区域的圆筒外壁进行测温，将所测温度数据整理后与模拟数据进行对比，发现实测与数值模拟数据变化趋势相似。将高频感应熔覆后的试验样品进行显微组织观察发现熔覆层与基体冶金结合良好，通过显微硬度测试试验发现冶金结合处的硬度最大，基体的硬度最小、摩擦磨损试验发现熔覆层的减摩性能优与基体的减摩性能、电化学腐蚀试验发现熔覆层比基体更耐腐蚀。

In this paper, the parameters of induction cladding process for the inner wall coating of cylindrical workpieces are numerically simulated using finite element numerical simulation analysis software in the context of the use environment of hydraulic bracket cylinders in coal mines, and a test platform is set up to conduct tests in order to obtain high quality copper alloy cladding. The main research of this paper is shown as follows:

First, based on the mathematical theoretical knowledge of Joule's heat law and Maxwell's system of equations, a finite element numerical simulation model of high-frequency induction cladding of copper alloy on the inner wall of a circular cylinder workpiece is established to simulate the high-frequency induction cladding process based on the available empirical test material parameters. The finite element numerical simulation analysis takes the electromagnetic-thermal coupling field as the core, and analyzes the electromagnetic field, temperature field and electromagnetic-thermal coupling field of the induction cladding copper alloy on the inner wall of the cylinder in turn. The practice of loading the heat source load directly on the surface of the cylinder without analyzing the electromagnetic field is improved, and the magnetic conductor is introduced into the analysis to improve the accuracy of the numerical simulation.

Secondly, the effect of each process parameter on the temperature distribution of the cylinder and the time to reach the melting temperature was investigated by numerical simulation of induction melting of copper alloy on the inner wall of the cylinder workpiece. It was found that the temperature of the copper alloy coating rises rapidly at the beginning of induction heating and gradually reaches a state where the temperature rise is no longer significantly dynamic equilibrium. The frequency of high-frequency induction heating, the size of the outer diameter of the high-frequency induction coil (the gap between the coil and the cladding layer), the power of the power supply, the coating thickness and the side length of the high-frequency induction coil section all have different effects on the induction cladding heating process.

Finally, the correctness of the numerical simulation was verified by an actual high-frequency induction cladding test. An infrared thermometer was used to continuously measure the temperature of the outer wall of the cylinder in the induction cladding area during the high-frequency induction cladding test. The measured temperature data was compiled and compared with the simulated data, and it was found that the measured and numerical simulation data had similar trends with an error of 8.6%. The microstructure of the test specimens after high-frequency induction cladding was observed and found that the metallurgical bonding was good. The microhardness test revealed that the hardness of the metallurgical bond was the highest and the hardness of the substrate was the lowest. The shear strength of the metallurgical bonding interface reached 152.4 MPa.

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