装载机虎头结构焊接顺序优化数值模拟分析
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摘要
装载机虎头存在突出的焊接变形问题,为了减小焊接变形,得到最优焊接顺序方案,利用热弹塑性有限元方法建立了有限元模型,并对装载机后车架虎头结构焊接变形进行了数值模拟计算.分析了虎头结构的四种变形趋势,定量地对比了不同焊接顺序下虎头结构各部位的最大焊接变形点,得到优化的焊接顺序.该顺序模拟结果:侧臂最大挠曲变形量为8 mm,框架扭转变形量为4 mm,侧臂收缩变形为12 mm.对预测的最佳焊接顺序下的变形模拟值和实测值进行了对比,结果表明,两者吻合良好.
Loader tiger exists a prominent question of welding deformation. To reduce this welding deformation and get the optimal scheme of tiger shaped structure welding sequence,the numerical simulation of welding deformation of tiger-shaped structure for rear frame of loader was conducted using thermo elastic-plastic method. The finite element model was established to analyze four kinds of deformation trend of tiger shaped structure and quantitatively calculate the distortion of different welding sequence, the optimal welding sequence of the whole structure was obtained. The results show that the maximum deflection distortion of side arm was 8 mm,the torsional deformation of frame was 4 mm,the in-plane shrinkage of side arm was 12 mm.The simulated values and measured values are compared under the optimal welding sequence,and the results show that they are in good agreement.
Loader tiger exists a prominent question of welding deformation. To reduce this welding deformation and get the optimal scheme of tiger shaped structure welding sequence,the numerical simulation of welding deformation of tiger-shaped structure for rear frame of loader was conducted using thermo elastic-plastic method. The finite element model was established to analyze four kinds of deformation trend of tiger shaped structure and quantitatively calculate the distortion of different welding sequence, the optimal welding sequence of the whole structure was obtained. The results show that the maximum deflection distortion of side arm was 8 mm,the torsional deformation of frame was 4 mm,the in-plane shrinkage of side arm was 12 mm.The simulated values and measured values are compared under the optimal welding sequence,and the results show that they are in good agreement.
引文
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[21]吴华英,郭成,王永信,等.轿车后围板成形过程数值模拟及参数优化[J].材料科学与工艺,2013,21(2):83-89.WU Huaying,GUO Cheng,WANG Yongxin,et al.Numerical simulation and parameter optimization in forming process of an automobile squab panel[J].Materials Science and Technology,2013,21(2):83-89.
[22]GANNON L,LIU Y,PEGG N,et al.Effect of welding sequence on residual stress and distortion in flatbar stiffened plates[J].Marine Structures,2010,23:385-404
[23]王兴路,贺利乐.焊接顺序对机械结构疲劳寿命影响研究[J].热加工工艺,2013,42(11):180-182+185.WANG Xinglu,HE Lile.Study on effect of welding sequence on fatigue life of mechanical structure[J].Hot Working Technology,2013,42(11):180-182,185.
[24]李晓东,李春广,朱志民,等.铝合金薄板MIG焊焊接变形仿真预测的工程应用[J].焊接学报,2014,35(2):104-108.LI Xiaodong,LI Chunguang,ZHU Zhimin,et al.Engineering applications of MIG welding deformation simulation of aluminum alloy sheet[J].Transactions of the China Welding Institution,2014,35(2):104-108.
[25]DONG Wenchao,LU Shanping,LU Hao,et al.Numerical simulation and control of welding distortion for double floor structure of high speed train[J].Acta Mechanica Sinica,2014,30(6):849-859.
[2]方洪渊.焊接结构学[M].北京:机械工业出版社,2008.FANG Hongyuan.Welded structure[M].Beijing:China Machine Press,2008.
[3]杨建国,万清华,戴志立,等.300MW锅炉汽包焊接变形的控制[J].焊接,1996,(11):14-16.YANG Jianguo,WAN Qinghua,DAI Zhili,et al.Controlling for welding distortion of 300 MW steam drum[J].Welding&Joining,1996,(11):14-16.
[4]NOH S,KASADA R,KIMURA A,et al.Microstructure and mechanical properties of friction stir processed ODS ferritic steels[J].Journal of Nuclear Materials,2011,417:245-248.
[5]薛忠明,曲文卿,柴鹏,等.焊接变形预测技术研究进展[J].焊接学报,2003,24(3):87-90.XUE Zhongming,QU Wenqing,CHAI Peng,et al.Review on prediction of welding distortion[J].Transactions of The China Welding Institution,2003,24(3):87-90.
[6]张志英,江志斌,虞成全.造船(中钢板)焊接变形的自动火焰矫正工艺系统[J].机械工程学报,2006,42(1):196-201.ZHANG Zhiying,JIANG Zhibin,YU Chengquan.Automated method of flame rectification process of welding distortion for mediate steel plate and system in shipbuilding[J].Chinese Journal of Mechanical Engineering,2006,42(1):196-201.
[7]SATTARI-FAR I,JAVADI Y.Influence of welding sequence on welding distortions in pipes[J].International Journal of Pressure Vessels and Piping,2008,85:265-274.
[8]徐济进,陈立功,汪建华,等.基于固有应变法筒体对接多道焊焊接变形的预测[J].焊接学报,2007,28(1):77-80.XU Jijin,CHEN Ligong,WANG Jianhua,et al.Prediction of distortion based on inherent strain method in multipass girth-butt welded pipes[J].Transactions of The China Welding Institution,2007,28(1):77-80.
[9]周广涛,刘雪松,闫德俊,等.顶板焊接顺序优化减小焊接变形的预测[J].焊接学报,2009,30(9):109-112.ZHOU Guangtao,LIU Xuesong,YAN Dejun,et al.Prediction for welding deformation reducing by welding sequence optimization of upper plate[J].Transactions of the China Welding Institution,2009,30(9):109-112.
[10]李军,张文锋.机械挤压矫正焊接变形的模拟与试验研究[J].材料科学与工艺,2013,21(1):134-137.LI Jun,ZHANG Wenfeng.Rectifying buckling distortion by extruding thin-plate weldments in parallel direction to weld[J].Materials Science and Technology,2013,21(1):134-137.
[11]张学秋,杨建国,刘雪松,等.焊接顺序对整体叶盘圆度影响的有限元分析[J].焊接学报,2010,31(3):57-60.ZHANG Xueqiu,YANG Jianguo,LIU Xuesong,et al.Finite element anlysis of welding sequence impact on blisk roundness[J].Transactions of The China Welding Institution,2010,31(3):57-60.
[12]黄海瀚,周广涛.装载机后车架焊接顺序优化的数值仿真[J].计算机辅助工程,2014,23(3):30-34.HUANG Hanhan,ZHOU Guangtao.Numerical simulation on welding sequence optimization of loader rear frame[J].Computer Aided Engineering,2014,23(3):30-34.
[13]王苹,王强,刘雪松,等.基于FEM的高速列车地板结构焊接顺序优化[J].焊接学报,2012,33(8):45-48,115.WANG Ping,WANG Qiang,LIU Xuesong,et al.Welding sequence optimization for high-speed rail floor based on FEM[J].Transactions of The China Welding Institution,2012,33(8):45-48,115.
[14]SOUTO GRELA J,BLANCO VIANA E B,MARTINEZ D,et al.Numerical simulation in welding process:optimizing structures with sequence and inertial study[J].Matériaux&Techniques,2012,100(4):317-326.
[15]任鹏,张伟,郭子涛,等.Numerical simulation for deformation of multi-layer steel plates under underwater impulsive loading[J].哈尔滨工业大学学报(英文版),2012,19(3):68-72.REN Peng,ZHANG Wei,GUO Zitao,et al.Numerical simulation for deformation of multi-layer steel plates under underwater impulsive loading[J].Journal of Harbin Institute of Technology,2012,19(3):68-72.
[16]李江飞,齐海波,任德亮,等.薄壁多焊缝复杂构件焊接过程的数值模拟[J].焊接学报,2015,36(1):87-90.LI Jiangfei,QI Haibo,REN Deliang,et al.Numerical simulation of welding process on thin-walled multiwelds complex component[J].Transactions of The China Welding Institution,2015,36(1):87-90.
[17]张伟玮,韩聪,苑世剑.高强钢22Mn B5扭力梁热成形热力耦合数值模拟[J].材料科学与工艺,2014,22(3):16-22.ZHANG Weiwei,HAN Cong,YUAN Shijian.Hot forming processing simulation of torsion beam of high strength steel 22Mn B5[J].Materials Science and Technology,2014,22(3):16-22.
[18]ISLAM M,BUIJK A,RAIS-ROHANI M,et al.Simulation-based numerical optimization of arc welding process for reduced distortion in welded structures[J].Finite Elements in Analysis and Design,2014,84:54-56.
[19]崔晓芳,林健,兆文忠.高速动力车构架侧梁焊接结构优化研究[J].材料科学与工艺,2004,12(6):606-609,614.CUI Xiaofang,LIN Jian,ZAO Wenzhong.Optimization of welded structure in bogie frame of high-speed locomotive[J].Materials Science and Technology,2004,12(6):606-609,614.
[20]GOLDAK J,CHAKRARTI A,BIBBY M.A new finite element model for welding heat sources[J].Metallurgical Materials Transactions B,1984,15(2):299-305.
[21]吴华英,郭成,王永信,等.轿车后围板成形过程数值模拟及参数优化[J].材料科学与工艺,2013,21(2):83-89.WU Huaying,GUO Cheng,WANG Yongxin,et al.Numerical simulation and parameter optimization in forming process of an automobile squab panel[J].Materials Science and Technology,2013,21(2):83-89.
[22]GANNON L,LIU Y,PEGG N,et al.Effect of welding sequence on residual stress and distortion in flatbar stiffened plates[J].Marine Structures,2010,23:385-404
[23]王兴路,贺利乐.焊接顺序对机械结构疲劳寿命影响研究[J].热加工工艺,2013,42(11):180-182+185.WANG Xinglu,HE Lile.Study on effect of welding sequence on fatigue life of mechanical structure[J].Hot Working Technology,2013,42(11):180-182,185.
[24]李晓东,李春广,朱志民,等.铝合金薄板MIG焊焊接变形仿真预测的工程应用[J].焊接学报,2014,35(2):104-108.LI Xiaodong,LI Chunguang,ZHU Zhimin,et al.Engineering applications of MIG welding deformation simulation of aluminum alloy sheet[J].Transactions of the China Welding Institution,2014,35(2):104-108.
[25]DONG Wenchao,LU Shanping,LU Hao,et al.Numerical simulation and control of welding distortion for double floor structure of high speed train[J].Acta Mechanica Sinica,2014,30(6):849-859.