考虑不确定性因素的不锈钢点焊车体焊点强度评估
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摘要
针对车体设计过程中以确定性模型分析焊点的焊接强度造成的分析结果局限性过大问题,提出了一种基于有限元理论和可靠性理论的焊点强度评估方法.考虑车体的结构尺寸和焊核直径等设计参数的不确定性,采用APDL语言建立参数化的有限元模型.基于AWS C1.1M/C1.1:2012标准编制Tcl脚本文件提取焊点的综合剪切强度,并结合D-最优试验设计,建立焊点强度与设计参数之间的函数关系.在此基础上,运用证据理论计算设计参数的样本点在相应区间的基本可信度分配,并根据可靠性理论进行焊点强度的可靠性分析.结果表明:在设计阶段考虑车体加工制造过程中的不确定性因素,弥补了基于确定性模型相对保守的缺陷,能够更加真实地反映列车的焊点强度;可靠性分析结果可为合理地设计焊点的安全系数提供了理论依据.
Aiming at the problem that the analysis results caused by the welding strength of the welding spot are too large for the deterministic model in the car body design process,a method for evaluating the welding spot strength based on finite element theory and reliability theory is proposed.Considering the uncertainties of design parameters such as structure size and weld nugget diameter of car body,a parameterized finite element model is established by using the APDL language.The comprehensive shear strength of the welding spot is extracted from the Tcl script file based on the AWS C1.1 M/C1.1:2012 standard,and combined with D-optimal experimental design,the functional relationship between welding spot strength and design parameters is established.On this basis,the basic probability assignment of sample points for design parameters in corresponding intervals is calculated by using evidence theory,and the reliability analysis of welding spot strength is carried out according to reliability theory.The results show that the uncertainty factors in the car body manufacturing process are considered in the design stage,which makes up for the relatively conservative defects based on the deterministic model,and can more accurately reflect the welding spot strength of the train.The reliability analysis results can provide a theoretical basis for the rational design of the safety factor of welding spot.
Aiming at the problem that the analysis results caused by the welding strength of the welding spot are too large for the deterministic model in the car body design process,a method for evaluating the welding spot strength based on finite element theory and reliability theory is proposed.Considering the uncertainties of design parameters such as structure size and weld nugget diameter of car body,a parameterized finite element model is established by using the APDL language.The comprehensive shear strength of the welding spot is extracted from the Tcl script file based on the AWS C1.1 M/C1.1:2012 standard,and combined with D-optimal experimental design,the functional relationship between welding spot strength and design parameters is established.On this basis,the basic probability assignment of sample points for design parameters in corresponding intervals is calculated by using evidence theory,and the reliability analysis of welding spot strength is carried out according to reliability theory.The results show that the uncertainty factors in the car body manufacturing process are considered in the design stage,which makes up for the relatively conservative defects based on the deterministic model,and can more accurately reflect the welding spot strength of the train.The reliability analysis results can provide a theoretical basis for the rational design of the safety factor of welding spot.
引文
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[13]SHAFER G.A mathematical theory of evidence[M].New Jersey:Princeton University Press,1976.
[14]ZHANG Z,JIANG C,WANG G G,et al.First and second order approximate reliability analysis methods using evidence theory[J].Reliability Engineering&System Safety,2015,137:40-49.
[15]MI J,LI Y F,YANG Y J,et al.Reliability assessment of complex electromechanical systems under epistemic uncertainty[J].Reliability Engineering&System Safety,2016,152:1-15.
[2]张志毅,韩晓辉,张中东,等.基于Swellam应力指数Ki的电阻点焊疲劳性能研究[J].兵器材料科学与工程,2018,41(1):70-73.ZHANG Z Y,HAN X H,ZHANG Z D,et al.Fatigue performance of resistance spot welds based on Swellam’s stress index Ki[J].Ordnance Material Science and Engineering,2018,41(1):70-73.
[3]张怡,饶建强.行李箱内板焊点耐久性开裂分析对策研究[J].现代制造工程,2015(6):70-74.ZHANG Y,RAO J Q.Analysis and countermeasure for spot of trunk inner plate cracked[J].Modern Manufacturing Engineering,2015(6):70-74.
[4]许娇.田爱琴,张文彬,等.全自动驾驶地铁不锈钢车体静强度和模态分析[J].大连交通大学学报,2017,38(2):34-38.XU J,TIAN A Q,ZHANG W B,et al.Static strength and modal analysis of stainless car body of automatic driving subway[J].Journal of Dalian Jiaotong University,2017,38(2):34-38.
[5]束洋.不锈钢车体侧墙激光焊缝排布及疲劳寿命分析[D].北京:北京交通大学,2017.SU Y.The layout and fatigue life analysis of laser welds for side wall of stainless steel car body[D].Beijing:Beijing Jiaotong University,2017.
[6]谢素明,穆伟,高阳.不锈钢点焊车体结构稳定性分析及局部焊点布局优化[J].大连交通大学学报,2017,34(4):12-16.XIE S M,MU W,GAO Y.Stability analysis and weld spots layout optimization for stainless steel spot weld carbody[J].Journal of Dalian Jiaotong University,2017,34(4):12-16.
[7]姚亚涛.不锈钢点焊车体结构仿真关键技术研究[D].成都:西南交通大学,2016.YAO Y T.Research on key technology of simulation of stainless steel spot welding car body structure[D].Chengdu:Southwest Jiaotong University,2016.
[8]孙芳芳,李萌盛,王洋,等.201不锈钢点焊过程的数值模拟[J].焊接学报,2011,32(2):21-24.SUN F F,LI M S,WANG Y,et al.Numerical simulation on 201stainless steel spot welding process[J].Transactions of the China Welding Institution,2011,32(2):21-24.
[9]British Standards Institution.Railway applications-structural requirements of railway vehicle bodies-locomotives and passenger rolling stock:BS EN 12663-1:2010[S].London:Standard Press of British,2010.
[10]British Standards Institution.Railway application-welding of railway vehicles and components parts 3:design requirements:BS EN 15085-3:2007[S].London:Standard Press of British,2007.
[11]America Welding Society.Recommended practices for resistance welding:AWS C1.1M/C1.1:2012[S].New York:American National Standards Institute,2012.
[12]程亚军,张春玉,谢素明.轨道车辆不锈钢车体焊点强度评估方法研究[J].大连交通大学学报,2018,39(2):43-47.CHENG Y J,ZHANG C Y,XIE S M.Strength evaluation method of spot welds of stainless car-body[J].Journal of Dalian Jiaotong University,2018,39(2):43-47.
[13]SHAFER G.A mathematical theory of evidence[M].New Jersey:Princeton University Press,1976.
[14]ZHANG Z,JIANG C,WANG G G,et al.First and second order approximate reliability analysis methods using evidence theory[J].Reliability Engineering&System Safety,2015,137:40-49.
[15]MI J,LI Y F,YANG Y J,et al.Reliability assessment of complex electromechanical systems under epistemic uncertainty[J].Reliability Engineering&System Safety,2016,152:1-15.