桥梁钢断裂韧性CTOD试验与仿真分析研究
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摘要
随着公路和铁路建设的迅猛发展,钢结构桥梁向大跨度、大节段、结构新颖美观方向发展,焊接结构呈现大型化、厚壁化的发展趋势,这就迫使工程人员采用高强度钢材和厚钢板。众所周知,母材和焊接接头的韧性不足,是焊接结构破坏的主要原因。厚钢板的大量采用会产生了一个与强度、刚度和稳定性同等重要的问题——厚钢板及其焊接接头的韧性控制。因此,准确评定厚钢板母材的韧性对于大型钢结构的防裂防断,确保其安全性,十分重要。本文采用数值模拟仿真与试验研究相结合的方法研究了桥梁用钢Q420qE和Q370qE的断裂韧性问题,主要研究内容和结论如下：
(1)针对东莞东江大桥设计要求,对主要桥梁用钢Q420qE和Q370qE力学性质进行了试验研究。选取两种主要桥梁结构钢材Q420qE和Q370qE以及焊接接头进行了常温力学性质的测试。获得了钢材Q420qE和Q370qE的拉伸曲线,测定了各种力学指标：屈服强度、极限强度、截面收缩率等参数。
(2)分别对各组CTOD试件进行了疲劳裂纹预制试验,在试验过程中,首先采用较大的恒幅疲劳载荷预制裂纹,然后采用较小的恒幅疲劳载荷对试件完成剩余裂纹预制工作,通过这种方法可以制得裂纹根部半径为零的疲劳裂纹,并且保证裂纹尖端不产生钝化,同时节约了大量的预制疲劳裂纹时间。在整个试验过程中,由疲劳试验机的控制微机记录了恒幅疲劳载荷的大小、加载时间、次数、频率等数据。
(3)分别对桥梁钢试件常温和低温下断裂韧度进行了试验研究。试验研究了不同厚度两种桥梁用钢Q420qE和Q370qE厚板试件同温度下的断裂行为,获得了含裂纹试件的P-V曲线,并对断口进行了测量,根据结果计算出桥梁用钢试件在不同温度下的裂纹尖端张开位移值。并且对试验结果进行了分析,讨论了板厚和温度对桥梁用钢Q420qE和Q370qE厚板试件CTOD断裂韧性的影响规律。断裂韧度CTOD试验结果表明：Q370qE母材、焊缝以及Q420qE母材、焊缝、热影响区试件的断裂韧性测试CTOD试验值受温度影响很大,在温度降低时,焊缝的断裂韧性下降急剧；而Q370qE热影响区断裂韧度受温度影响不明显；同时,试件的CTOD值跟板厚关系密切。
(4)基于线弹性断裂力学的基本理论,运用疲劳分析软件对CTOD试件进行裂纹扩展分析,考虑到裂纹尖端处的应力奇异性,在利用有限元方法计算穿透裂纹的应力强度因子时,裂尖区域选用了20结点三维等参奇异单元,可以保证结果的收敛性。通过数值模拟,本文建立了不同尺寸材料的试件裂纹长度与循环次数关系曲线。通过仿真值与试验值对比表明选用以线弹性断裂力学为基础的软件计算桥梁钢试件疲劳预制裂纹过程的正确性。
(5)对金属材料断裂韧性测试中运用的数值仿真方法的基本理论进行了总结和分析,在采用有限元软件ANSYS和LS-DYNA对CTOD试件的断裂韧性计算结果与试验相比较的基础上,证明了ANSYS和LS-DYNA对桥梁用钢的断裂韧性试验的三维数值模拟问题的有效性和可行性。通过计算仿真工作发现选用显式积分法软件LS-DYNA处理准静态断裂破坏问题比隐式通用软件ANSYS具有更高的精度和可靠性,并且计算过程中,在保证计算精度的前提下,可以通过适当的提高加载速度来缩短计算时间。同时本文研究了仿真计算模拟下的网格尺寸的选取和精度、计算时间控制的问题,通过研究结果,得出了桥梁用钢断裂韧性CTOD试验三维数值模拟计算的网格划分尺度,有效的解决了利用有限元软件LS-DYNA在金属材料韧性计算研究上时间与精度上的优化。
(6)通过参考国内外CTOD韧性测试规范和重要文献,根据桥梁安全级别、重要性和服役温度,对桥梁用钢厚板CTOD允许值进行了探讨,并对重大工程东江桥厚板焊接接头断裂韧度作出评估。同时断裂韧度CTOD推荐值可以为其他厚板结构以及焊接接头的断裂韧度评判提供参考。
With the rapid development of railway and highway in the recently 100 years, the construction of steel bridge will become large-span, large segment, novel style structural. In large span bridge design, because of their link force received increase, we have to use the thick plate if we choose traditional steel or use the high strength. At the same time, their work environment become worse and worse, the application of larger engineering project appear with using the high strength steel and thick plate in large amount engineering. The incident of common steel structure and welded connection which are made by the high strength steel and thick plate appear brittle fracture become more frequently. Therefore the problem come to us:the fracture toughness evaluation and control for steel structural need to research which is also very important to the problem of material strength stiffness, stability. As we known, the fracture toughness weakness of the heat affected zone and welded connection is the main reason of failure of welded structure, the thick of steel plate, the weak fracture toughness is. Therefore, the accurate evaluation fracture toughness of thick steel plate is extremely important to the anti-fracture of large span steel bridge. In this research, this paper use numerical simulation method and CTOD experimentation for bridge steel Q420qE and Q370qE to evaluation their fracture toughness, and the following efforts have been made and the conclusions are presented:
(1) This research measured the mechanical behavior of bridge structural steel which was needed for the design of Dongguan east river bridge were undertook. The environmental and physical condition is determinate by the temperature region where the Dongguan east river in. This paper choosed two important bridge structural steel Q420qE and Q370qE of different thick plate and the welded seam material to do the research on their mechanical properties. This investigation can get various mechanical parameter from tests, for example:yield strength, ultimate strength, section shrinkage rate and percentage elongation and'so on.
(2) At the same time, the CTOD specimens fatigue crack were made for each group specimens. in the test, firstly,these specimens were under larger fatigue load; at last,residual fatigue crack were made by smaller fatigue load. In this method, a lot of time was saved, the radious of crack which is equal to zero was made, and the crack tip was not in passivation. At the same time, the relationship of the load, crack extend growth, load cycle and frequency were record.
(3) The bridge structure steel Q420qE and Q370qE of different thickness in different temperature were under fracture behavior test, the P-V curve were obtain from the specimens which contain crack, the change rule which are influence by the test temperature and the thickness of specimens were obtain from the change crack open displacement. The value of CTOD was under investigation from its accuracy and practicability, furthemore, the CTOD value of different bridge steel specimen which is affected by the change of temperature greatly is analyzed, and the crack open displacement value is close related to temperature and thick is presented. we can come to the conclusion that:except for Q370qE HAZ specimens, the fracture toughness CTOD value of bridge steel Q420qE and Q370qE specimens are greatly influenced by the test temperature, at the same time, when the base steel specimens, heated affect zone specimens and welded seam specimens are under the environment when the temperature is down quickly, the fracture toughness of welded seam specimens are the most sensitive, and all of CTOD value of the specimens is closed to the thickness of specimens.
(4)Based on the linear-elastic fracture mechanics, considering the stress strange of the crack tip, the 3D 20 point special element was made for crack tip when use the FEM to compute the KI. using fatigue software to anlysis the crack growth of CTOD specimens, found the relationship of the load,crack extend growth, load cycle, the result were show that using fatigue to compute the bridge steel fatigue crack growth was right.
(5) The investigation show that using finite element software ANSYS and LS-DYNA to solve the calculation of the fracture toughness of metal bridge material is correct and feasible which is basing on contrast of CTOD value and the fracture toughness test CTOD value. And the value computed by LS-DYNA is better than by ANSYS. The basic theory and numerical simulation method which is used in the fracture toughness test of metal material have been in research and summary, the mesh size, time control and precision control has been studied. From the investigation, it can come to the conclusion that the selection of mesh size are determine which are used in the three dimensional numerical simulation about the fracture toughness test of metal bridge material, from this investigation, the optimization problem between the mesh size, loading speed, using time,and precision control in the fracture toughness calculation of metal material by using universal large commercial finite element software LS-DYNA is under solution.
(6) Based on the CTOD various criterion and thesis in the world, considering the security level and work temperature, the permit value of CTOD of bridge steel thick plate was under discussion. The major engineering project steel and welded seam of east river fracture toughness property was evaluation. At the same time, the permit value of CTOD is also can use in other project fracture toughness evaluation.
(1)针对东莞东江大桥设计要求,对主要桥梁用钢Q420qE和Q370qE力学性质进行了试验研究。选取两种主要桥梁结构钢材Q420qE和Q370qE以及焊接接头进行了常温力学性质的测试。获得了钢材Q420qE和Q370qE的拉伸曲线,测定了各种力学指标：屈服强度、极限强度、截面收缩率等参数。
(2)分别对各组CTOD试件进行了疲劳裂纹预制试验,在试验过程中,首先采用较大的恒幅疲劳载荷预制裂纹,然后采用较小的恒幅疲劳载荷对试件完成剩余裂纹预制工作,通过这种方法可以制得裂纹根部半径为零的疲劳裂纹,并且保证裂纹尖端不产生钝化,同时节约了大量的预制疲劳裂纹时间。在整个试验过程中,由疲劳试验机的控制微机记录了恒幅疲劳载荷的大小、加载时间、次数、频率等数据。
(3)分别对桥梁钢试件常温和低温下断裂韧度进行了试验研究。试验研究了不同厚度两种桥梁用钢Q420qE和Q370qE厚板试件同温度下的断裂行为,获得了含裂纹试件的P-V曲线,并对断口进行了测量,根据结果计算出桥梁用钢试件在不同温度下的裂纹尖端张开位移值。并且对试验结果进行了分析,讨论了板厚和温度对桥梁用钢Q420qE和Q370qE厚板试件CTOD断裂韧性的影响规律。断裂韧度CTOD试验结果表明：Q370qE母材、焊缝以及Q420qE母材、焊缝、热影响区试件的断裂韧性测试CTOD试验值受温度影响很大,在温度降低时,焊缝的断裂韧性下降急剧；而Q370qE热影响区断裂韧度受温度影响不明显；同时,试件的CTOD值跟板厚关系密切。
(4)基于线弹性断裂力学的基本理论,运用疲劳分析软件对CTOD试件进行裂纹扩展分析,考虑到裂纹尖端处的应力奇异性,在利用有限元方法计算穿透裂纹的应力强度因子时,裂尖区域选用了20结点三维等参奇异单元,可以保证结果的收敛性。通过数值模拟,本文建立了不同尺寸材料的试件裂纹长度与循环次数关系曲线。通过仿真值与试验值对比表明选用以线弹性断裂力学为基础的软件计算桥梁钢试件疲劳预制裂纹过程的正确性。
(5)对金属材料断裂韧性测试中运用的数值仿真方法的基本理论进行了总结和分析,在采用有限元软件ANSYS和LS-DYNA对CTOD试件的断裂韧性计算结果与试验相比较的基础上,证明了ANSYS和LS-DYNA对桥梁用钢的断裂韧性试验的三维数值模拟问题的有效性和可行性。通过计算仿真工作发现选用显式积分法软件LS-DYNA处理准静态断裂破坏问题比隐式通用软件ANSYS具有更高的精度和可靠性,并且计算过程中,在保证计算精度的前提下,可以通过适当的提高加载速度来缩短计算时间。同时本文研究了仿真计算模拟下的网格尺寸的选取和精度、计算时间控制的问题,通过研究结果,得出了桥梁用钢断裂韧性CTOD试验三维数值模拟计算的网格划分尺度,有效的解决了利用有限元软件LS-DYNA在金属材料韧性计算研究上时间与精度上的优化。
(6)通过参考国内外CTOD韧性测试规范和重要文献,根据桥梁安全级别、重要性和服役温度,对桥梁用钢厚板CTOD允许值进行了探讨,并对重大工程东江桥厚板焊接接头断裂韧度作出评估。同时断裂韧度CTOD推荐值可以为其他厚板结构以及焊接接头的断裂韧度评判提供参考。
With the rapid development of railway and highway in the recently 100 years, the construction of steel bridge will become large-span, large segment, novel style structural. In large span bridge design, because of their link force received increase, we have to use the thick plate if we choose traditional steel or use the high strength. At the same time, their work environment become worse and worse, the application of larger engineering project appear with using the high strength steel and thick plate in large amount engineering. The incident of common steel structure and welded connection which are made by the high strength steel and thick plate appear brittle fracture become more frequently. Therefore the problem come to us:the fracture toughness evaluation and control for steel structural need to research which is also very important to the problem of material strength stiffness, stability. As we known, the fracture toughness weakness of the heat affected zone and welded connection is the main reason of failure of welded structure, the thick of steel plate, the weak fracture toughness is. Therefore, the accurate evaluation fracture toughness of thick steel plate is extremely important to the anti-fracture of large span steel bridge. In this research, this paper use numerical simulation method and CTOD experimentation for bridge steel Q420qE and Q370qE to evaluation their fracture toughness, and the following efforts have been made and the conclusions are presented:
(1) This research measured the mechanical behavior of bridge structural steel which was needed for the design of Dongguan east river bridge were undertook. The environmental and physical condition is determinate by the temperature region where the Dongguan east river in. This paper choosed two important bridge structural steel Q420qE and Q370qE of different thick plate and the welded seam material to do the research on their mechanical properties. This investigation can get various mechanical parameter from tests, for example:yield strength, ultimate strength, section shrinkage rate and percentage elongation and'so on.
(2) At the same time, the CTOD specimens fatigue crack were made for each group specimens. in the test, firstly,these specimens were under larger fatigue load; at last,residual fatigue crack were made by smaller fatigue load. In this method, a lot of time was saved, the radious of crack which is equal to zero was made, and the crack tip was not in passivation. At the same time, the relationship of the load, crack extend growth, load cycle and frequency were record.
(3) The bridge structure steel Q420qE and Q370qE of different thickness in different temperature were under fracture behavior test, the P-V curve were obtain from the specimens which contain crack, the change rule which are influence by the test temperature and the thickness of specimens were obtain from the change crack open displacement. The value of CTOD was under investigation from its accuracy and practicability, furthemore, the CTOD value of different bridge steel specimen which is affected by the change of temperature greatly is analyzed, and the crack open displacement value is close related to temperature and thick is presented. we can come to the conclusion that:except for Q370qE HAZ specimens, the fracture toughness CTOD value of bridge steel Q420qE and Q370qE specimens are greatly influenced by the test temperature, at the same time, when the base steel specimens, heated affect zone specimens and welded seam specimens are under the environment when the temperature is down quickly, the fracture toughness of welded seam specimens are the most sensitive, and all of CTOD value of the specimens is closed to the thickness of specimens.
(4)Based on the linear-elastic fracture mechanics, considering the stress strange of the crack tip, the 3D 20 point special element was made for crack tip when use the FEM to compute the KI. using fatigue software to anlysis the crack growth of CTOD specimens, found the relationship of the load,crack extend growth, load cycle, the result were show that using fatigue to compute the bridge steel fatigue crack growth was right.
(5) The investigation show that using finite element software ANSYS and LS-DYNA to solve the calculation of the fracture toughness of metal bridge material is correct and feasible which is basing on contrast of CTOD value and the fracture toughness test CTOD value. And the value computed by LS-DYNA is better than by ANSYS. The basic theory and numerical simulation method which is used in the fracture toughness test of metal material have been in research and summary, the mesh size, time control and precision control has been studied. From the investigation, it can come to the conclusion that the selection of mesh size are determine which are used in the three dimensional numerical simulation about the fracture toughness test of metal bridge material, from this investigation, the optimization problem between the mesh size, loading speed, using time,and precision control in the fracture toughness calculation of metal material by using universal large commercial finite element software LS-DYNA is under solution.
(6) Based on the CTOD various criterion and thesis in the world, considering the security level and work temperature, the permit value of CTOD of bridge steel thick plate was under discussion. The major engineering project steel and welded seam of east river fracture toughness property was evaluation. At the same time, the permit value of CTOD is also can use in other project fracture toughness evaluation.
引文
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