不同有限元软件对Q390钢厚板T型接头焊接残余应力和变形预测精度与计算效率的比较
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摘要
以Q390高强钢厚板多层多道焊T型接头为研究对象,分别基于ABAQUS、MARC和SYSWELD三款不同的有限元软件平台,开发"热-弹-塑性有限元方法"模拟接头的焊接温度场、残余应力与焊接变形。采用理论方法检验三种数值模拟软件在计算焊接温度场时的热量损失情况。结果表明,通过ABAQUS软件进行多层多道焊温度场的计算时,在后续焊道单元的添加和激活过程中,会造成热量的损失,对此提出了相应的解决方案;另外两个软件对焊接温度场的计算不存在热量损失问题。同时,采用试验方法实测接头的焊接残余应力和焊接变形。通过对比数值模拟结果与试验结果可知,三种不同的数值模拟软件对焊接残余应力都有较高的预测精度。对于焊接变形,ABAQUS的预测精度最高,然而计算时间最长;MARC次之,与ABAQUS相比计算效率提高了55%;SYSWELD对多层多道焊焊接变形的预测精度相对较差,但其计算效率最高,与ABAQUS相比效率提高了66%。为充分利用各个软件的优势进行焊接数值模拟的研究提供了较好的借鉴和参考价值。
Thermal-elastic-plastic finite element computational approaches are developed based on three kinds of different finite element method(FEM) software, namely ABAQUS, MARC and SYSWELD, and the welding temperature field, residual stress and welding deformation of a tick-plate Q390 steel T-joint are simulated. The heat loss of three kinds of numerical analysis software in the calculation of welding temperature field is tested by theoretical method. The results show that when the temperature field of multi-pass welding is calculated by ABAQUS software, the heat loss will be caused during the adding and activation of the following weld beads. There is no heat loss problem in the calculation of welding temperature field by the other two kinds of software. In the current study, the welding residual stress and welding deformation of the T-joint are measured by experiment. Based on the comparison between the simulation results and the experimental measurements, we can know that three different kinds of software all have sufficient accuracy to model the welding residual stress. For welding deformation, ABAQUS has the highest prediction accuracy,but its calculation time is the longest. MARC takes the second place, with 55% improvement in computational efficiency compared to ABAQUS. SYSWELD has a relatively poor prediction accuracy for welding deformation of multi-pass welded joint, but its calculation efficiency is the highest, with a 66% increase compared to ABAQUS. The results obtained by the present study would be of meaningful reference value for the study of welding numerical simulation by making full use of the advantages of various kinds of software.
Thermal-elastic-plastic finite element computational approaches are developed based on three kinds of different finite element method(FEM) software, namely ABAQUS, MARC and SYSWELD, and the welding temperature field, residual stress and welding deformation of a tick-plate Q390 steel T-joint are simulated. The heat loss of three kinds of numerical analysis software in the calculation of welding temperature field is tested by theoretical method. The results show that when the temperature field of multi-pass welding is calculated by ABAQUS software, the heat loss will be caused during the adding and activation of the following weld beads. There is no heat loss problem in the calculation of welding temperature field by the other two kinds of software. In the current study, the welding residual stress and welding deformation of the T-joint are measured by experiment. Based on the comparison between the simulation results and the experimental measurements, we can know that three different kinds of software all have sufficient accuracy to model the welding residual stress. For welding deformation, ABAQUS has the highest prediction accuracy,but its calculation time is the longest. MARC takes the second place, with 55% improvement in computational efficiency compared to ABAQUS. SYSWELD has a relatively poor prediction accuracy for welding deformation of multi-pass welded joint, but its calculation efficiency is the highest, with a 66% increase compared to ABAQUS. The results obtained by the present study would be of meaningful reference value for the study of welding numerical simulation by making full use of the advantages of various kinds of software.
引文
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[16]蔡建鹏,叶延洪,张彦杰,等.坡口形式对Q345/SUS304异种钢对接接头残余应力和变形的影响[J].机械工程学报,2015,51(10):55-61.CAI Jianpeng,YE Yanhong,ZHANG Yanjie,et al.Study on influences of groove type on welding residual stress and deformation in Q345/SUS304 dissimilar steel butt-welded joints[J].Journal of Mechanical Engineering,2015,51(10):55-61.
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[18]ABAQUS Analysis Research Corporation.Abaqus analysis user’s guide[M].Providence,Rhodes,USA:Rhode Island,2016.
[2]SHIGA C,MURAKAWA H,HIRAOKA K,et al.Elongated bead weld method for improvement of fatigue properties in welded joints of ship hull structures using low transformation temperature welding materials[J].Welding in the World,2017,61(4):769-788.
[3]BOEHM L.New engineering processes in aircraft construction:Application of laser-beam and friction stir welding[J].Glass Physics&Chemistry,2005,31(1):27-29.
[4]UEDA Y.Welding deformation and residual stress prevention[M].Oxford:Elsevier LTD,2012.
[5]YAN D Y,WU A P,SILVANUS J,et al.Predicting residual distortion of aluminum alloy stiffened sheet after friction stir welding by numerical simulation[J].Materials&Design,2011,32(4):2284-2291.
[6]MURAKAWA H,SANO M,WANG J.Influence of root gap and tack weld on transverse shrinkage during welding[J].Transactions of JWRI,2012,41(1):65-70.
[7]HWANG S Y,KIM Y,LEE J H.Finite element analysis of residual stress distribution in a thick plate joined using two-pole tandem electro-gas welding[J].Journal of Materials Processing Technology,2016,229(2016):349-360.
[8]ZHU X K,CHAO Y J.Effects of temperature-dependent material properties on welding simulation[J].Computers&Structures,2002,80(11):967-976.
[9]LI Y,WANG K,JIN Y,et al.Prediction of welding deformation in stiffened structure by introducing thermo-mechanical interface element[J].Journal of Materials Processing Tech.,2015,216:440-446.
[10]邓德安,KIYOSHIMA Shoichi.退火温度对SUS304不锈钢焊接残余应力计算精度的影响[J].金属学报,2014,50(5):626-632.DENG Dean,KIYOSHIMA Shoichi.Influence of annealing temperature on calculation accuracy of welding residual stress in a SUS304 stainless steel joint[J].Acta Metallurgica Sinica,2014,50(5):626-632.
[11]DENG D,ZHANG C,PU X,et al.Influence of material model on prediction accuracy of welding residual stress in an austenitic stainless steel multi-pass butt-welded joint[J].Journal of Materials Engineering&Performance,2017,26(4):1494-1505.
[12]RONG Y,ZHANG G,HUANG Y.Study of welding distortion and residual stress considering nonlinear yield stress curves and multi-constraint equations[J].Journal of Materials Engineering&Performance,2016,25(10):1-11.
[13]LEE C H,CHANG K H.Numerical analysis of residual stresses in welds of similar or dissimilar steel weldments under superimposed tensile loads[J].Computational Materials Science,2007,40(4):548-556.
[14]叶延洪,孙加民,蔡建鹏,等.焊缝屈服强度对SM490A钢焊接残余应力预测精度的影响[J].焊接学报,2015,36(7):17-20.YE Yanhong,SUN Jiamin,CAI Jianpeng,et al.Influence of yield strength of weld metal on prediction accuracy of welding residual stress in SM490A steel joint[J].Transactions of the China Welding Institution,2015,36(7):17-20.
[15]SUN J,LIU X,TONG Y,et al.A comparative study on welding temperature fields,residual stress distributions and deformations induced by laser beam welding and CO2,gas arc welding[J].Materials&Design,2014,63(2):519-530.
[16]蔡建鹏,叶延洪,张彦杰,等.坡口形式对Q345/SUS304异种钢对接接头残余应力和变形的影响[J].机械工程学报,2015,51(10):55-61.CAI Jianpeng,YE Yanhong,ZHANG Yanjie,et al.Study on influences of groove type on welding residual stress and deformation in Q345/SUS304 dissimilar steel butt-welded joints[J].Journal of Mechanical Engineering,2015,51(10):55-61.
[17]DENG D.FEM prediction of welding residual stress and distortion in carbon steel considering phase transformation effects[J].Materials and Design,2009,30:359-66.
[18]ABAQUS Analysis Research Corporation.Abaqus analysis user’s guide[M].Providence,Rhodes,USA:Rhode Island,2016.