同一截面焊接结构完整性理论与试验研究
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摘要
随着焊接工艺水平的提高，“一刀齐”总段合拢工艺已应用于国内大型船企民用船舶建造中。“一刀齐”对接工艺的采用，为分段无余量合拢提供了有利条件，极大的减轻了两段船体在船台上合拢的工作量，有效缩短了产品研制时间和生产周期。但是，采用“一刀齐”对接工艺后船体的强度、刚度、残余应力和焊接变形、疲劳寿命等是否会有较大影响，影响程度如何等关键技术并没有进行过深入的研究和探讨。
本文在理论研究和试验对比的基础上，建立了典型焊接接头焊接残余应力数值预报方法，分析了典型焊接接头焊接残余应力的分布规律及其对结构极限强度的影响；基于多尺度理论拟合得出了含裂纹典型焊接接头极限强度计算公式；引入新R6失效评判图对典型焊接接头开展了失效评判，计算了典型焊接接头在某荷载下的临界裂纹长度；进行了不同初始裂纹长度下典型焊接接头的疲劳寿命预报；开展了典型焊接结构极限强度和疲劳强度试验研究。通过论文的系统研究，取得了一下主要研究成果：
1）通过平板对接焊数值模拟和试验值的对比分析，建立了典型焊接接头焊接过程有限元数值模拟的方法和流程。进而开展了不同对接工艺典型焊接接头的焊接温度场、应力场的数值模拟研究，获得了不同对接工艺典型焊接接头的焊接温度场、应力场的分布规律和各自的特点。
2）针对不同边界固定方式、不同焊材强度匹配对典型焊接接头焊接残余应力场和位移场的影响开展研究。研究结果表明，不同的边界固定方式会使不同对接工艺下的典型焊接接头的焊接残余应力场和位移场重新分布，但对于残余应力和焊接变形的最大值没有影响；采用不同焊材强度匹配对焊接残余应力有一定的影响，不同匹配间的最大差值为80MPa。
3）把多尺度理论与有限元技术相结合的方法用于含微裂纹缺陷结构极限承载能力研究。利用本构逼近法，把含微裂纹缺陷结构极限承载能力研究过程划分成介观尺寸模型研究和宏观尺寸模型研究两部分进行研究；把含微裂纹介观尺寸模型作为典型焊接接头的宏观结构中区别于常规材料属性的部分嵌套至整体模型中参与计算，并建立了基于L4的正交表计算方案，开展典型焊接接头整体结构的极限强度计算。
4）基于大量的算例，拟合得出了包含相对裂纹长度（RCL）、裂纹分布深度(CD)和裂纹分布比例(CRD)三个变量不同对接形式下典型焊接接头极限强度计算公式。基于极限强度拟合公式，分别开展了相对裂纹长度（RCL）、裂纹分布深度(CD)和裂纹分布比例(CRD)变量对典型焊接接头极限承载能力影响的研究。同时，也开展了焊接残余应力对结构极限强度的影响研究。
5）利用新R6失效评定图的失效评定方法，对典型焊接接头进行了失效评定。通过失效评定，获得了典型焊接接头随初始裂纹长度变化的失效路径曲线。根据失效路径曲线可以得到不同对接形式的对接接头的临界初始裂纹长度。同时，针对第三章提出的焊接结构允许最小裂纹长度进行了失效评定研究，研究结果为结构的完整性评估提供了有力的参考。
6）根据新R6失效评定图的方法,开展了典型焊接接头在167MPa、220MPa、335MPa和418MPa四种工作应力水平下的失效评定研究。通过失效评定研究，获得了四种工作应力水平下典型焊接接头的临界裂纹尺寸，并把获得的各评判点的裂纹临界尺寸与试验测试结果进行了对比分析，两者吻合较好。
7）针对上述采用的微裂纹尺度，开展了含初始裂纹典型焊接接头的疲劳寿命预报。通过疲劳寿命预报，获得了初始裂纹长度与疲劳寿命的关系曲线，并根据典型焊接接头的疲劳试验结果与预报的疲劳寿命进行对比分析，获得了试验结构的初始裂纹长度。
With the improvement of the level of welding technology.“welded connection in-plane”block assembly technology has been applied to civil ship construction of domestic largeshipping enterprises. The use of “welded connection in-plane” assembly technology providesfavorable conditions for segment no allowance assembly, reduces the workload of two hullsassembling on the shipway greatly and shortens the product development time and productioncycle effectively. However, after adopting new technologies, whether the strength of the hull,stiffness, residual stress and welding deformation, fatigue life and so on will have greaterimpact later and how is the influence degree and so on have not been researched anddiscussed in depth.
In this paper, on the basis of theoretical research and experimental comparison,numerical prediction method of residual stress of typical welded joint was established anddistribution rule and its impact on the ultimate strength of structure was also analyzed. Basedon the multi-scale theory, the formula of ultimate strength of typical welded joint with crackwas obtained through a large number of calculations. Failure evaluation on typical weldedjoint was carried out through introducing new R6failure judgment figure and the criticalcrack length was calculated. Fatigue life prediction under different initial crack lengths andthe ultimate and fatigue strength experimental research of typical welded joint were carriedout. Through the systematic study of the paper, the main research results are as follows:
1) Through the comparison between numerical simualtion and experimental value ofplate butt welding, the finite element numerical simualtion method of the welding process oftypical welded joint was established. The numerical simualtion research on weldingtemperature field, stress field of typical welded joint under different docking technologies wascarried out and the distribution and characteristics of welding temperature field, stress field oftypical welded joint was obtained.
2) The influence of different matches of boundary fixed way and welding materialstrength on residual stress and displacement fields was researched. Results show that residualstress and displacement fields of typical welded joint under different docking technologiesand boundary fixed ways will redistribute, but the maximum value of residual stress anddisplacement are not influenced. Different welding material strength matches has a certaininfluence on residual stress, between which the maximum difference value is80MPa.
3) The method of combining multi-scale theory with finite element technology wasapplied to ultimate bearing capacity of defect structure with micro crack. Process of thisresearch was divided into two parts using constitutive approximation method, namelymesoscopic and macro size model. Using constitutive approximation method, mesoscopic sizemodel of plate with micro crack was as the part different from conventional material propertyin the macro structure of typical welded joint. Basic orthogonal table calculation scheme wasestablished and then ultimate strength of the overall structure was calculated.
4) Formula of ultimate strength of typical welded joint under different docking formsincluding three variables of relative crack length(RCL), crack distribution depth(CD) andproportion(CRD)was obtained through a large number of calculations. Based on formula ofultimate strength, influence of relative crack length(RCL), crack distribution depth(CD) andproportion(CRD) on ultimate bearing capacity of typical welded joint were carriedrespectively. And the influence of welding residual stress on ultimate strength of structure wasresearched.
5) Based on the failure evaluation results of new R6failure judgment figure, failureevaluation on typical welded joint was carried on. The failure path curve was obtained byfailure evaluation. According to the ailure path curve, the critical initial crack length of typicalwelded joint was obtained. The research on minimum crack length which proposed at chapterthree was carried on. The results of the study provides a powerful reference for structureintegrity assessment.
6) Failure evaluation on typical welded joint under four stress levels of167MPa,220MPa,335MPa and418MPa was carried on based on new R6failure judgment method.Critical crack sizes of different working conditions were obtained by failure evaluation. Crackcritical size of evaluation point obtained from new R6failure judgment figure was comparedwith test result. It also coincides well with experimental result.
7) According to the micro crack size adopted above, fatigue life prediction on typicalwelded joint with initial crack was carried out. Through the prediction, relation curve betweeninitial crack length and fatigue life was obtained. Initial crack length of the actual structurewas also obtained through the comparison between fatigue test result and fatigue lifeprediction value of typical welded joint.
本文在理论研究和试验对比的基础上，建立了典型焊接接头焊接残余应力数值预报方法，分析了典型焊接接头焊接残余应力的分布规律及其对结构极限强度的影响；基于多尺度理论拟合得出了含裂纹典型焊接接头极限强度计算公式；引入新R6失效评判图对典型焊接接头开展了失效评判，计算了典型焊接接头在某荷载下的临界裂纹长度；进行了不同初始裂纹长度下典型焊接接头的疲劳寿命预报；开展了典型焊接结构极限强度和疲劳强度试验研究。通过论文的系统研究，取得了一下主要研究成果：
1）通过平板对接焊数值模拟和试验值的对比分析，建立了典型焊接接头焊接过程有限元数值模拟的方法和流程。进而开展了不同对接工艺典型焊接接头的焊接温度场、应力场的数值模拟研究，获得了不同对接工艺典型焊接接头的焊接温度场、应力场的分布规律和各自的特点。
2）针对不同边界固定方式、不同焊材强度匹配对典型焊接接头焊接残余应力场和位移场的影响开展研究。研究结果表明，不同的边界固定方式会使不同对接工艺下的典型焊接接头的焊接残余应力场和位移场重新分布，但对于残余应力和焊接变形的最大值没有影响；采用不同焊材强度匹配对焊接残余应力有一定的影响，不同匹配间的最大差值为80MPa。
3）把多尺度理论与有限元技术相结合的方法用于含微裂纹缺陷结构极限承载能力研究。利用本构逼近法，把含微裂纹缺陷结构极限承载能力研究过程划分成介观尺寸模型研究和宏观尺寸模型研究两部分进行研究；把含微裂纹介观尺寸模型作为典型焊接接头的宏观结构中区别于常规材料属性的部分嵌套至整体模型中参与计算，并建立了基于L4的正交表计算方案，开展典型焊接接头整体结构的极限强度计算。
4）基于大量的算例，拟合得出了包含相对裂纹长度（RCL）、裂纹分布深度(CD)和裂纹分布比例(CRD)三个变量不同对接形式下典型焊接接头极限强度计算公式。基于极限强度拟合公式，分别开展了相对裂纹长度（RCL）、裂纹分布深度(CD)和裂纹分布比例(CRD)变量对典型焊接接头极限承载能力影响的研究。同时，也开展了焊接残余应力对结构极限强度的影响研究。
5）利用新R6失效评定图的失效评定方法，对典型焊接接头进行了失效评定。通过失效评定，获得了典型焊接接头随初始裂纹长度变化的失效路径曲线。根据失效路径曲线可以得到不同对接形式的对接接头的临界初始裂纹长度。同时，针对第三章提出的焊接结构允许最小裂纹长度进行了失效评定研究，研究结果为结构的完整性评估提供了有力的参考。
6）根据新R6失效评定图的方法,开展了典型焊接接头在167MPa、220MPa、335MPa和418MPa四种工作应力水平下的失效评定研究。通过失效评定研究，获得了四种工作应力水平下典型焊接接头的临界裂纹尺寸，并把获得的各评判点的裂纹临界尺寸与试验测试结果进行了对比分析，两者吻合较好。
7）针对上述采用的微裂纹尺度，开展了含初始裂纹典型焊接接头的疲劳寿命预报。通过疲劳寿命预报，获得了初始裂纹长度与疲劳寿命的关系曲线，并根据典型焊接接头的疲劳试验结果与预报的疲劳寿命进行对比分析，获得了试验结构的初始裂纹长度。
With the improvement of the level of welding technology.“welded connection in-plane”block assembly technology has been applied to civil ship construction of domestic largeshipping enterprises. The use of “welded connection in-plane” assembly technology providesfavorable conditions for segment no allowance assembly, reduces the workload of two hullsassembling on the shipway greatly and shortens the product development time and productioncycle effectively. However, after adopting new technologies, whether the strength of the hull,stiffness, residual stress and welding deformation, fatigue life and so on will have greaterimpact later and how is the influence degree and so on have not been researched anddiscussed in depth.
In this paper, on the basis of theoretical research and experimental comparison,numerical prediction method of residual stress of typical welded joint was established anddistribution rule and its impact on the ultimate strength of structure was also analyzed. Basedon the multi-scale theory, the formula of ultimate strength of typical welded joint with crackwas obtained through a large number of calculations. Failure evaluation on typical weldedjoint was carried out through introducing new R6failure judgment figure and the criticalcrack length was calculated. Fatigue life prediction under different initial crack lengths andthe ultimate and fatigue strength experimental research of typical welded joint were carriedout. Through the systematic study of the paper, the main research results are as follows:
1) Through the comparison between numerical simualtion and experimental value ofplate butt welding, the finite element numerical simualtion method of the welding process oftypical welded joint was established. The numerical simualtion research on weldingtemperature field, stress field of typical welded joint under different docking technologies wascarried out and the distribution and characteristics of welding temperature field, stress field oftypical welded joint was obtained.
2) The influence of different matches of boundary fixed way and welding materialstrength on residual stress and displacement fields was researched. Results show that residualstress and displacement fields of typical welded joint under different docking technologiesand boundary fixed ways will redistribute, but the maximum value of residual stress anddisplacement are not influenced. Different welding material strength matches has a certaininfluence on residual stress, between which the maximum difference value is80MPa.
3) The method of combining multi-scale theory with finite element technology wasapplied to ultimate bearing capacity of defect structure with micro crack. Process of thisresearch was divided into two parts using constitutive approximation method, namelymesoscopic and macro size model. Using constitutive approximation method, mesoscopic sizemodel of plate with micro crack was as the part different from conventional material propertyin the macro structure of typical welded joint. Basic orthogonal table calculation scheme wasestablished and then ultimate strength of the overall structure was calculated.
4) Formula of ultimate strength of typical welded joint under different docking formsincluding three variables of relative crack length(RCL), crack distribution depth(CD) andproportion(CRD)was obtained through a large number of calculations. Based on formula ofultimate strength, influence of relative crack length(RCL), crack distribution depth(CD) andproportion(CRD) on ultimate bearing capacity of typical welded joint were carriedrespectively. And the influence of welding residual stress on ultimate strength of structure wasresearched.
5) Based on the failure evaluation results of new R6failure judgment figure, failureevaluation on typical welded joint was carried on. The failure path curve was obtained byfailure evaluation. According to the ailure path curve, the critical initial crack length of typicalwelded joint was obtained. The research on minimum crack length which proposed at chapterthree was carried on. The results of the study provides a powerful reference for structureintegrity assessment.
6) Failure evaluation on typical welded joint under four stress levels of167MPa,220MPa,335MPa and418MPa was carried on based on new R6failure judgment method.Critical crack sizes of different working conditions were obtained by failure evaluation. Crackcritical size of evaluation point obtained from new R6failure judgment figure was comparedwith test result. It also coincides well with experimental result.
7) According to the micro crack size adopted above, fatigue life prediction on typicalwelded joint with initial crack was carried out. Through the prediction, relation curve betweeninitial crack length and fatigue life was obtained. Initial crack length of the actual structurewas also obtained through the comparison between fatigue test result and fatigue lifeprediction value of typical welded joint.
引文
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