地铁焊接构架残余应力和焊接变形研究
|
摘要
本课题以孟买地铁项目为背景,分析了不同的焊接工艺对地铁转向架侧梁焊接残余应力的影响,以及采用何种焊接顺序使得转向架侧梁的焊接变形最小等问题。
考虑到经济因素和可操作性,本课题使用T型板来替代转向架侧梁作为研究对象,研究不同的焊接工艺对焊接残余应力的影响。通过红外热像仪测量了T型板在焊接过程中的温度场分布,获得T型板的焊接温度循环曲线,采用盲孔法测得T型板的焊接残余应力。实验完成后,采用有限元模拟计算加以验证。并且发现,TIG熔修能一定程度的降低焊缝中心的残余应力,但增大了熔修区域的残余应力;而通过整体热处理能有效地消除熔修带来的大部分残余应力。另外,实验获得的数据结果反过来验证了有限元计算方法的准确性。
最后采用同样的有限元计算方法对地铁转向架侧梁进行模拟,得到了不同焊接顺序下侧梁焊接变形的具体数据,为工程实际工作提供了依据。
Based on the program of Mumbai subway, the research analyzes the influence of different welding procedure on residual stress of side beam, and how to choose the welding sequence to make sure the deformation of the side beam is the smallest.
Considering the economic factors and maneuverability, T-joint plates are used to replace the side beam in order to research the influence of different welding procedure on residual stress. The welding temperature field of T-joint plates was measured by using an infrared thermal imager, and the thermal cycles were experienced during welding were achieved; the residual stress of T-joint plates were measured by blind-hole method. After the experiment, the finite element method was used to verify the results. The results showed that the method of TIG remelting could limitedly Lower the residual stress in seam center area, but the residual stress in remelting area were increased. However, by the overall heat treatment much residual stress brought by TIG remelting could be eliminated effectively. In addition, the experimental results also verified the accuracy of the finite element method.
At last, the same finite element method was used to simulate the welding process on the side beam of the subway; and the data about welding deformation of side beam welded by different welding sequence was acquired, which provide the basis for practical work.
考虑到经济因素和可操作性,本课题使用T型板来替代转向架侧梁作为研究对象,研究不同的焊接工艺对焊接残余应力的影响。通过红外热像仪测量了T型板在焊接过程中的温度场分布,获得T型板的焊接温度循环曲线,采用盲孔法测得T型板的焊接残余应力。实验完成后,采用有限元模拟计算加以验证。并且发现,TIG熔修能一定程度的降低焊缝中心的残余应力,但增大了熔修区域的残余应力;而通过整体热处理能有效地消除熔修带来的大部分残余应力。另外,实验获得的数据结果反过来验证了有限元计算方法的准确性。
最后采用同样的有限元计算方法对地铁转向架侧梁进行模拟,得到了不同焊接顺序下侧梁焊接变形的具体数据,为工程实际工作提供了依据。
Based on the program of Mumbai subway, the research analyzes the influence of different welding procedure on residual stress of side beam, and how to choose the welding sequence to make sure the deformation of the side beam is the smallest.
Considering the economic factors and maneuverability, T-joint plates are used to replace the side beam in order to research the influence of different welding procedure on residual stress. The welding temperature field of T-joint plates was measured by using an infrared thermal imager, and the thermal cycles were experienced during welding were achieved; the residual stress of T-joint plates were measured by blind-hole method. After the experiment, the finite element method was used to verify the results. The results showed that the method of TIG remelting could limitedly Lower the residual stress in seam center area, but the residual stress in remelting area were increased. However, by the overall heat treatment much residual stress brought by TIG remelting could be eliminated effectively. In addition, the experimental results also verified the accuracy of the finite element method.
At last, the same finite element method was used to simulate the welding process on the side beam of the subway; and the data about welding deformation of side beam welded by different welding sequence was acquired, which provide the basis for practical work.
引文
[1] Gurney T G, Fatigue of welded structures, Publ Cambridge University Press, Cambridge, 1979(2nd ed).
[2]徐灏,疲劳强度.北京:机械工业出版社,1981.
[3] IIW/IIS-693-81(ex DOC.XIII-998-81XV-494-81), Design Recommendation for Cyclic Loaded Welded Steel Structures, Welding in the World,1982,20(7/8).
[4] Hobbacher A, The Development of the New IIW Fatigue Recommendations, IIW 50th Annual Assembly Conference,1997.
[5]王东坡,尹丹青,超声冲击法提高T型焊接管接头疲劳性能.天津大学学报,2006,6(39),757~762.
[6]尹丹青,王东坡,杨倩,双周疲劳载荷作用下超声冲击处理态焊接接头疲劳行为,天津大学学报,2009,(10).
[7]王东坡,霍立兴,张玉凤,超声冲击法对钛合金焊接接头疲劳性能的改善,中国有色金属学报,2003,6.
[8]贾安东,焊接结构与生产,北京:机械工业出版社.
[9]任富明.机车与城轨车辆转向架构架焊接技术分析.铁道机车车辆工人,2009,(5):1-5.
[10] Horn A. M., Huther I. , Lieurade H. P. . Fatigue behaviour of T-joints improved by TIG dressing. Welding in the Word,1998,41:273~280.
[11]杨明,厚板焊接残余应力的有限元计算,硕士学位论文,北京工业大学,2003.
[12]中国机械工程学会焊接学会,焊接手册第三卷,北京:机械工业出版社,2008,138~139.
[13]崔晓芳,箱型结构焊接变形预测、控制及应用,大连交通大学,博士学位论文,2004.
[14]汪建华.焊接变形和残余应力预测理论与计算-发展及应用前景,第三届计算机在焊接中的应用技术交流会论文集,上海:2000.13~19.
[15]赵智云,宽厚比超限的焊接工字形构件残余应力试验研究与有限元分析,硕士学位论文,西安建筑科技大学,2011.
[16]黄晶,刘宇光,张涛等,厚板焊接残余应力的试验研究,中国舰船研究,2009,4(5),33~37.
[17]熊健民,周金枝,余天庆.厚板焊接中焊接残余应力的分布规律.湖北工学院学报, 1997( 3) : 5~10.
[18]徐琳,严仁军,T形焊接接头残余应力与变形的三维数值模拟,江苏船舶,2007,24(1).
[19]汪建华,管板接头三维焊接变形的数值模拟,焊接学报,1995,16(3):140~145.
[20] H. Alberg, Simulation of Welding and Heat Treatment: Modeling and Validation, Doctoral thesis, Lule? University of Technology, 2005.
[21]董俊慧,霍立兴,张玉凤,环焊缝管道焊接应力应变三维有限元分析,机械工程学报,2001,37(12),86~89.
[22]汪建华,陆皓,局部焊后热处理最佳加热条件的研究(一)一种基于粘弹塑性有限元分析的直接评定方法,压力容器,1999,16(1):14~17.
[23] H. Alberg, D. Berglund, CoMParison of plastic, viscoplastic and creep models when modeling welding and stress relief heat treatment, Comput. Methods Appl. Mech. Engrg. 2003, 192: 5189-5208.
[24] W. Jianhua, L. Hao, Hidekazu MURAKAWA, Mechanical behavior in local post weld heat treatment (Report I)– Visco-Elastic-Plastic FEM analysis of local PWHT, Trans. JWRI, 1998, 27 (1):24~29.
[25]周跃庆,张媛媛,程亦晗.感应淬火电磁热耦合场的有限元分析.金属热处理,2007,32(2).
[26]董俊慧,霍立兴,张玉凤,环焊缝管道焊接应力应变三维有限元分析,机械工程学报,2001,37(12),86~89.
[27] B. Brickstad, B. L. Josefson, A parametric study of residual stresses in multi-pass butt-welded stainless steel pipes, International journal of pressure vessels and piping, 1998, 75: 11~25.
[28]黎超文,王勇,韩涛,焊接顺序对T形接头残余应力和变形的影响,焊接学报,2011,(10).
[29]王泽军,球形储罐局部消应力热处理的机理与效果评价研究,博士学位论文,天津大学,2007.
[30] ANSYS Inc, ANSYS Release 8.0 documentation.
[31]李东林,焊接应力和变形的数值模拟研究,硕士学位论文,武汉理工大学,2003.
[32]肖冯,米彩盈,T型角接头焊接热源模型研究,电焊机,第40卷第六期.
[33]王悦,朱明日,郑双.基于RS-485/MODBUS的特种焊机通信系统.电焊机,2008,38(5):1~5.
[34]郭豪.高速转向架T型接头焊趾TIG重熔工艺研究,硕士学位论文,大连:大连交通大学,2007.
[35]贾法勇,不锈钢与铝合金焊接接头疲劳评定的热点应力方法及局部法研究,博士学位论文,天津大学,2004.
[36]球形储罐局部消应力热处理的机理与效果评价研究,博士学位论文,天津大学,2007.
[37]潘家祯,压力容器材料实用手册-碳钢及合金钢,北京:化学工业出版社,2000.
[38]李煜,复合钢板压力容器焊缝高温蠕变研究,硕士学位论文,太原理工大学,2010.
[39]阮星谊,包晔峰,石忠贤,焊接变形测量方法. Electric Welding Machine,2005,5(35),55~57.
[40]蔡志鹏,赵海燕,吴苏等,串热源模型及其在焊接数值模拟中的应用.机械工程学报.2001,37(4):25-28.
[41]张朝晖,ANSYS热分析教程与实例解析,北京:中国铁道出版社,2007,2~3.
[42]周春亮,P92钢焊接温度场及应力场的数值模拟,硕士学位论文,天津大学,2008.
[43]刘波,姚河清,移动热载荷在焊接温度场数值模拟中的应用,河海大学学报(自然科学版),2008,36(3):405~409.
[44]李冬林,焊接应力和变形的数值模拟研究,硕士学位论文,武汉理工大学,2003,3.
[45]王长利,焊接温度场和应力场的数值模拟,硕士学位论文,沈阳工业大学,2005.
[2]徐灏,疲劳强度.北京:机械工业出版社,1981.
[3] IIW/IIS-693-81(ex DOC.XIII-998-81XV-494-81), Design Recommendation for Cyclic Loaded Welded Steel Structures, Welding in the World,1982,20(7/8).
[4] Hobbacher A, The Development of the New IIW Fatigue Recommendations, IIW 50th Annual Assembly Conference,1997.
[5]王东坡,尹丹青,超声冲击法提高T型焊接管接头疲劳性能.天津大学学报,2006,6(39),757~762.
[6]尹丹青,王东坡,杨倩,双周疲劳载荷作用下超声冲击处理态焊接接头疲劳行为,天津大学学报,2009,(10).
[7]王东坡,霍立兴,张玉凤,超声冲击法对钛合金焊接接头疲劳性能的改善,中国有色金属学报,2003,6.
[8]贾安东,焊接结构与生产,北京:机械工业出版社.
[9]任富明.机车与城轨车辆转向架构架焊接技术分析.铁道机车车辆工人,2009,(5):1-5.
[10] Horn A. M., Huther I. , Lieurade H. P. . Fatigue behaviour of T-joints improved by TIG dressing. Welding in the Word,1998,41:273~280.
[11]杨明,厚板焊接残余应力的有限元计算,硕士学位论文,北京工业大学,2003.
[12]中国机械工程学会焊接学会,焊接手册第三卷,北京:机械工业出版社,2008,138~139.
[13]崔晓芳,箱型结构焊接变形预测、控制及应用,大连交通大学,博士学位论文,2004.
[14]汪建华.焊接变形和残余应力预测理论与计算-发展及应用前景,第三届计算机在焊接中的应用技术交流会论文集,上海:2000.13~19.
[15]赵智云,宽厚比超限的焊接工字形构件残余应力试验研究与有限元分析,硕士学位论文,西安建筑科技大学,2011.
[16]黄晶,刘宇光,张涛等,厚板焊接残余应力的试验研究,中国舰船研究,2009,4(5),33~37.
[17]熊健民,周金枝,余天庆.厚板焊接中焊接残余应力的分布规律.湖北工学院学报, 1997( 3) : 5~10.
[18]徐琳,严仁军,T形焊接接头残余应力与变形的三维数值模拟,江苏船舶,2007,24(1).
[19]汪建华,管板接头三维焊接变形的数值模拟,焊接学报,1995,16(3):140~145.
[20] H. Alberg, Simulation of Welding and Heat Treatment: Modeling and Validation, Doctoral thesis, Lule? University of Technology, 2005.
[21]董俊慧,霍立兴,张玉凤,环焊缝管道焊接应力应变三维有限元分析,机械工程学报,2001,37(12),86~89.
[22]汪建华,陆皓,局部焊后热处理最佳加热条件的研究(一)一种基于粘弹塑性有限元分析的直接评定方法,压力容器,1999,16(1):14~17.
[23] H. Alberg, D. Berglund, CoMParison of plastic, viscoplastic and creep models when modeling welding and stress relief heat treatment, Comput. Methods Appl. Mech. Engrg. 2003, 192: 5189-5208.
[24] W. Jianhua, L. Hao, Hidekazu MURAKAWA, Mechanical behavior in local post weld heat treatment (Report I)– Visco-Elastic-Plastic FEM analysis of local PWHT, Trans. JWRI, 1998, 27 (1):24~29.
[25]周跃庆,张媛媛,程亦晗.感应淬火电磁热耦合场的有限元分析.金属热处理,2007,32(2).
[26]董俊慧,霍立兴,张玉凤,环焊缝管道焊接应力应变三维有限元分析,机械工程学报,2001,37(12),86~89.
[27] B. Brickstad, B. L. Josefson, A parametric study of residual stresses in multi-pass butt-welded stainless steel pipes, International journal of pressure vessels and piping, 1998, 75: 11~25.
[28]黎超文,王勇,韩涛,焊接顺序对T形接头残余应力和变形的影响,焊接学报,2011,(10).
[29]王泽军,球形储罐局部消应力热处理的机理与效果评价研究,博士学位论文,天津大学,2007.
[30] ANSYS Inc, ANSYS Release 8.0 documentation.
[31]李东林,焊接应力和变形的数值模拟研究,硕士学位论文,武汉理工大学,2003.
[32]肖冯,米彩盈,T型角接头焊接热源模型研究,电焊机,第40卷第六期.
[33]王悦,朱明日,郑双.基于RS-485/MODBUS的特种焊机通信系统.电焊机,2008,38(5):1~5.
[34]郭豪.高速转向架T型接头焊趾TIG重熔工艺研究,硕士学位论文,大连:大连交通大学,2007.
[35]贾法勇,不锈钢与铝合金焊接接头疲劳评定的热点应力方法及局部法研究,博士学位论文,天津大学,2004.
[36]球形储罐局部消应力热处理的机理与效果评价研究,博士学位论文,天津大学,2007.
[37]潘家祯,压力容器材料实用手册-碳钢及合金钢,北京:化学工业出版社,2000.
[38]李煜,复合钢板压力容器焊缝高温蠕变研究,硕士学位论文,太原理工大学,2010.
[39]阮星谊,包晔峰,石忠贤,焊接变形测量方法. Electric Welding Machine,2005,5(35),55~57.
[40]蔡志鹏,赵海燕,吴苏等,串热源模型及其在焊接数值模拟中的应用.机械工程学报.2001,37(4):25-28.
[41]张朝晖,ANSYS热分析教程与实例解析,北京:中国铁道出版社,2007,2~3.
[42]周春亮,P92钢焊接温度场及应力场的数值模拟,硕士学位论文,天津大学,2008.
[43]刘波,姚河清,移动热载荷在焊接温度场数值模拟中的应用,河海大学学报(自然科学版),2008,36(3):405~409.
[44]李冬林,焊接应力和变形的数值模拟研究,硕士学位论文,武汉理工大学,2003,3.
[45]王长利,焊接温度场和应力场的数值模拟,硕士学位论文,沈阳工业大学,2005.