构架管接头焊缝参数对疲劳缺口应力的影响
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摘要
为了克服整体法进行焊接结构强度设计时造成的母材强度过剩,焊缝强度不足的问题,采用局部缺口应力法,分析了焊缝各局部参数对疲劳应力的影响程度;目的是在不改变整体结构参数的前提下,通过优化焊缝设计参数,实现焊接结构疲劳强度的提高。文章以某动车焊接构架为研究对象,建立了横梁管焊接接头的多尺度模型。以参数化的1mm虚拟缺口模型分析了各焊缝参数变化以及砂轮打磨半径对于缺口应力集中系数的影响规律,结果表明焊趾角度的影响较焊喉深度更为显著,而砂轮磨削的最佳半径为6mm。以构架整体模型分析了焊接接头在各疲劳工况下的实际受力情况,联合各向缺口应力集中系数并采用形状改变能密度准则计算了管接头焊趾处的多轴等效缺口应力。通过与原焊缝设计参数相比较,减小15°的焊趾角度能够降低10%的疲劳缺口应力,6mm的磨削半径则能够降低超过20%的疲劳缺口应力。
In order to overcome the problem of strength surplus of base metal and insufficient strength of weld caused by using global approach when design of the structure strength, the local notch stress approach in this paper is used to study the effect degree of weld parameters to fatigue stress,which purpose is to improve the fatigue strength by optimizing weld parameters but without changing overall structure. It chooses a welded frame of powered bogie as the research object,then the multi-scale models of tube-to-plate joint from the frame are established. In a parameterized local notch model of 1mm fictitious radii,the variation of stress concentration factors(SCF)are analyzed with different weld parameters and burr grinding radii, it shows that weld toe angle has more significant influence on SCF than weld throat depth, and the 6mm grinding radius is considered the most reasonable. The force situation of tube-to-plate joint in some actual cases are got by overall FE model,and then the multi axis equivalent notch stress is calculated which also combined the notch SCF and distortional strain energy criterion.Comparing with the result of original weld design parameter,the fatigue notch stress will reduce 10% when the toe angle decrease 15°,and the 6mm grinding radius can lead to fatigue stress reduced more than 20%.
In order to overcome the problem of strength surplus of base metal and insufficient strength of weld caused by using global approach when design of the structure strength, the local notch stress approach in this paper is used to study the effect degree of weld parameters to fatigue stress,which purpose is to improve the fatigue strength by optimizing weld parameters but without changing overall structure. It chooses a welded frame of powered bogie as the research object,then the multi-scale models of tube-to-plate joint from the frame are established. In a parameterized local notch model of 1mm fictitious radii,the variation of stress concentration factors(SCF)are analyzed with different weld parameters and burr grinding radii, it shows that weld toe angle has more significant influence on SCF than weld throat depth, and the 6mm grinding radius is considered the most reasonable. The force situation of tube-to-plate joint in some actual cases are got by overall FE model,and then the multi axis equivalent notch stress is calculated which also combined the notch SCF and distortional strain energy criterion.Comparing with the result of original weld design parameter,the fatigue notch stress will reduce 10% when the toe angle decrease 15°,and the 6mm grinding radius can lead to fatigue stress reduced more than 20%.
引文
[1]周张义.机车车辆焊接结构疲劳分析关键问题研究[J].机车电传动,2008(1):28-36.(Zhou Zhang-yi,Study on key points in fatigue analysis for welded structures of rolling stock[J].Electric Drive for Locomotives,2008(1):28-36.)
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[5]米彩盈,李芾.基于谱载荷的高速列车转向架构架的疲劳强度[J].西南交通大学学报,2006,41(3):381-385.(Mi Cai-ying,Li Fu.Fatigue strength of bogie frame of high-speed train under spectrum load[J].Journal of Southwest Jiaotong University,2006,41(3):381-385.)
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[7]Sonsino C M.Notch stress concepts for the fatigue assessment of welded joints-Background and applications[J].International Journal of Fatigue,2012(34):2-16.
[8]Radaj D,Lazzarin P,Berto F.Generalized Neuber concept of fictitious notch rounding[J].International Journal of Fatigue,2013(51):105-115.
[9]Kassner M.Fatigue strength analysis of a welded railway vehicle structure by different methods[J].International Journal of Fatigue,2012(34):103-111.
[10]Lazzarin P,Tovo R.A unified approach to the evaluation of linear elastic stress fields in the neighborhood cracks and notches[J].International journal of Fracture,1996(78):3-19.
[11]周张义,李芾,安琪.钢结构焊缝疲劳强度分析技术的最新进展[J].中国铁道科学,2009,30(4):69-74.(Zhou Zhang-yi,Li Fu,An Qi.Latest development of fatigue strength analysis technology for welds in steel structures[J].China Railway Science,2009,30(4):69-74.)
[12]Baumgartner J,Bruder T.An efficient meshing approach for the calculation of notch stresses[J].Weld World,2013(57):137-145.
[13]任富明.HXD1B型机车转向架构架制造工艺分析[J].机车车辆工艺,2009(3):18-19.(Ren Fu-ming.The manufacturing process analysis of HXD1B locomotive bogie frame[J].Locomotive&Rolling Stock Technology,2009(3):18-19.)
[14]Sonsino C M.Multiaxial fatigue of welded joints under in-phase and out-of-phase local strains and stresses[J].International Journal of Fatigue,1995,1(17):37-145.
[15]刘旭,张开林,姚远.基于缺口理论的复杂焊接结构疲劳分析方法[C].第23届全国结构工程学术会议论文集(第Ⅰ册),北京:中国力学学会工程力学编辑部,2014:190-197.(Liu Xu,Zhang Kai-lin,Yao Yuan.The fatigue analysis method of complex weld structure base on notch theory.23rd national conference of structural engineering(Ⅰ),Beijing:Chinese Mechanical Society and Engineering Mechanics Editorial Department,2014:190-197.)
[16]刘旭,张开林,姚远.缺口应力法在机车焊接构架疲劳分析中的应用[J].铁道学报,2015,37(1):1-6.(Liu Xu,Zhang Kai-lin,Yao Yuan.Application of notch stress method in fatigue analysis of locomotive welded frame[J].Journal of the China Railway Society,2015,37(1):1-6.)
[17]邱宝象,高增梁,王效贵.基于有限元法的16Mn R缺口件疲劳寿命预测方法[J].工程力学,2010,27(8):21-27.(Qiu Bao-xiang,Gao Zeng-liang,Wang Xiao-gui.A fatigue life prediction method for 6Mnr steel notched components based on the finite element method[J].Engineering Mechanics,2010,27(8):21-27.)
[18]吴志荣,胡绪腾,宋迎东.多轴载荷下缺口件的疲劳寿命估算方法[J].工程力学,2014,31(10):216-221.(Wu Zhi-rong,Hu Xu-teng,Song Ying-dong.Estimation method for fatigue life of notched specimen under multi-axial loading[J].Engineering Mechanics,2014,31(10):216-221.)
[2]李晓峰,谢素明,时慧焯.车辆焊接结构疲劳寿命评估方法研究[J].中国铁道科学,2007,28(3):74-78.(Li Xiao-feng,Xie Su-ming,Shi Hui-zhuo.Study on the analysis method for fatigue life prediction of vehicle welded structure[J].China Railway Science,2007,28(3):74-78.)
[3]王文静,刘志明,李强.CRH2动车转向架构架疲劳强度分析[J].北京交通大学学报,2009,31(1):5-9.(Wang Wen-jing,Liu Zhi-ming,Li Qiang.Fatiguestrength analysis of CRH2motor bogie frame[J].Journal of Beijing Jiaotong University,2009,31(1):5-9.)
[4]谢素明,时慧焯,李娅娜.基于IIW标准的提速客车转向架焊接构架疲劳寿命预测[J].大连铁道学院学报,2006,27(3):17-21.(Xie Su-ming,Shi Hui-zhuo,Li Ya-na.Fatigue life prediction for weld frame of speed-up bogie based on IIW standard[J].Journal of Dalian Railway Institute,2006,27(3):17-21.)
[5]米彩盈,李芾.基于谱载荷的高速列车转向架构架的疲劳强度[J].西南交通大学学报,2006,41(3):381-385.(Mi Cai-ying,Li Fu.Fatigue strength of bogie frame of high-speed train under spectrum load[J].Journal of Southwest Jiaotong University,2006,41(3):381-385.)
[6]秦国栋,刘志明,崔二光.提速转向架焊接构架疲劳寿命的实用分析方法[J].中国铁道科学,2004,25(1):47-51.(Qin Guo-dong,Liu Zhi-ming,Cui Er-guang.Practical analysis method for fatigue life of weld ed frame of speed-up bogie[J].China Railway Science,2004,25(1):47-51.)
[7]Sonsino C M.Notch stress concepts for the fatigue assessment of welded joints-Background and applications[J].International Journal of Fatigue,2012(34):2-16.
[8]Radaj D,Lazzarin P,Berto F.Generalized Neuber concept of fictitious notch rounding[J].International Journal of Fatigue,2013(51):105-115.
[9]Kassner M.Fatigue strength analysis of a welded railway vehicle structure by different methods[J].International Journal of Fatigue,2012(34):103-111.
[10]Lazzarin P,Tovo R.A unified approach to the evaluation of linear elastic stress fields in the neighborhood cracks and notches[J].International journal of Fracture,1996(78):3-19.
[11]周张义,李芾,安琪.钢结构焊缝疲劳强度分析技术的最新进展[J].中国铁道科学,2009,30(4):69-74.(Zhou Zhang-yi,Li Fu,An Qi.Latest development of fatigue strength analysis technology for welds in steel structures[J].China Railway Science,2009,30(4):69-74.)
[12]Baumgartner J,Bruder T.An efficient meshing approach for the calculation of notch stresses[J].Weld World,2013(57):137-145.
[13]任富明.HXD1B型机车转向架构架制造工艺分析[J].机车车辆工艺,2009(3):18-19.(Ren Fu-ming.The manufacturing process analysis of HXD1B locomotive bogie frame[J].Locomotive&Rolling Stock Technology,2009(3):18-19.)
[14]Sonsino C M.Multiaxial fatigue of welded joints under in-phase and out-of-phase local strains and stresses[J].International Journal of Fatigue,1995,1(17):37-145.
[15]刘旭,张开林,姚远.基于缺口理论的复杂焊接结构疲劳分析方法[C].第23届全国结构工程学术会议论文集(第Ⅰ册),北京:中国力学学会工程力学编辑部,2014:190-197.(Liu Xu,Zhang Kai-lin,Yao Yuan.The fatigue analysis method of complex weld structure base on notch theory.23rd national conference of structural engineering(Ⅰ),Beijing:Chinese Mechanical Society and Engineering Mechanics Editorial Department,2014:190-197.)
[16]刘旭,张开林,姚远.缺口应力法在机车焊接构架疲劳分析中的应用[J].铁道学报,2015,37(1):1-6.(Liu Xu,Zhang Kai-lin,Yao Yuan.Application of notch stress method in fatigue analysis of locomotive welded frame[J].Journal of the China Railway Society,2015,37(1):1-6.)
[17]邱宝象,高增梁,王效贵.基于有限元法的16Mn R缺口件疲劳寿命预测方法[J].工程力学,2010,27(8):21-27.(Qiu Bao-xiang,Gao Zeng-liang,Wang Xiao-gui.A fatigue life prediction method for 6Mnr steel notched components based on the finite element method[J].Engineering Mechanics,2010,27(8):21-27.)
[18]吴志荣,胡绪腾,宋迎东.多轴载荷下缺口件的疲劳寿命估算方法[J].工程力学,2014,31(10):216-221.(Wu Zhi-rong,Hu Xu-teng,Song Ying-dong.Estimation method for fatigue life of notched specimen under multi-axial loading[J].Engineering Mechanics,2014,31(10):216-221.)