液压支架双伸缩立柱的应力分析和疲劳寿命预测
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摘要
立柱是液压支架的主要承载构件之一,其强度和疲劳寿命对煤矿的安全生产起着至关重要的作用,进行液压支架立柱的应力分析及其疲劳寿命预测对提高立柱的使用寿命及其工作可靠性具有极其重要的意义。目前,立柱的应力分析和疲劳寿命预测多凭借经验或理论计算,其结果的准确性差。而利用计算机仿真技术进行的应力分析或寿命预测,将有效降低开发成本、缩短开发周期、提高其可靠性水平。
论文通过立柱失效的资料,进行了失效形式及其失效机理的分析,提出焊缝疲劳失效是立柱的主要失效形式的结论。论文按照MT313-1992《液压支架立柱技术条件》标准,在1.5倍轴向载荷和1.1倍偏心载荷下对双伸缩立柱进行应力测试；并利用UG建模软件和ANSYS有限元分析软件建立立柱的实体模型和有限元模型,在相同的载荷条件下对其进行有限元分析,比较应力测试结果与有限元分析结果,验证有限元分析结论的可信度。
论文基于双伸缩立柱的焊缝结构进行研究,从试验和仿真两个方面对其进行了应力分析,以实测载荷历程,采用局部应力应变法对不同焊缝结构的立柱进行疲劳寿命预测,得到立柱各部分的疲劳寿命和安全系数,并比较焊缝坡口类型和角度对立柱疲劳寿命的影响。
通过双伸缩立柱的仿真分析,得到了不同焊缝结构、工况条件下双伸缩立柱的应力和疲劳寿命,为液压支架立柱的设计和使用提供了理论依据。论文在UG环境下生成焊缝的方法和利用ANSYS耦合节点自由度模拟焊接连接的方法,为其它工程焊接件的仿真提供了方法和依据。
Column is one of the main bearing structure in hydraulic support, its strength and fatigue life plays a vital role to safety production in coal mine. For hydraulic support column the to improve the service life of the pillar with its working reliability and important meaning.It is of extremely important meaning to proceed stress analysis and fatigue life prediction of hydraulic support's column. Now, the stress analysis and fatigue life prediction of double-telescopic props are proceeded by relying on experience or theoretical calculation, the result accuracy is poor. The stress analysis and fatigue life prediction proceeded by the computer simulation technology can help to reduce development costs, shorten the development cycle and improve reliability level.
The failure forms and failure mechanism of double-telescopic props are analyzed through collecting material and put forward that weld fatigue failure is the main failure forms of column. In accordance with the standards MT313-1992 "technology conditions of hydraulic support column", stress of double-telescopic props with 1.5 times axial load and eccentric loads 1.1 times are tested; The entity model and finite element model are built by using UG modeling software and ANSYS finite element analysis software; In the same conditions of loading, the finite element analysis are done; The reliability of finite element analysis are verified by comparing test results and finite element analysis results.
The research is preceeded based on the weld structure of double-telescopic props in this paper. Stress analysis are done from two aspects:test and simulation, and to stress analysis results for load process the fatigue life are predicted by using the method of local stress strain gauge. And the influence of weld structure and stress concentration to double-telescopic props strength is considered.Last, on the basic of s-n curve and load spectrum curve, the fatigue life prediction of double-telescopic props with different weld structure are proceeded by using method of local stress strain gauge through ANSYS/FE-SAFE fatigue module to get of fatigue life and safety coefficient on each part of double-telescopic props and compare the influence to fatigue life of double-telescopic props brought by weld groove type and angle to get fatigue life and safety coefficient on each part of column and compare the influence to fatigue life of column brought by weld groove type and angle.
The stress and fatigue life of double-telescopic under different weld structure and working condition are obtained through the simulation and analysis, which can provide theoretical basis for the design and use of double-telescopic props.The method on weld generation in UG environment and the simulation way on welding connection through coupling freedom of nodes in ANSYS are also introduced in this paper,who can provide method and basis for other engineering simulation.
论文通过立柱失效的资料,进行了失效形式及其失效机理的分析,提出焊缝疲劳失效是立柱的主要失效形式的结论。论文按照MT313-1992《液压支架立柱技术条件》标准,在1.5倍轴向载荷和1.1倍偏心载荷下对双伸缩立柱进行应力测试；并利用UG建模软件和ANSYS有限元分析软件建立立柱的实体模型和有限元模型,在相同的载荷条件下对其进行有限元分析,比较应力测试结果与有限元分析结果,验证有限元分析结论的可信度。
论文基于双伸缩立柱的焊缝结构进行研究,从试验和仿真两个方面对其进行了应力分析,以实测载荷历程,采用局部应力应变法对不同焊缝结构的立柱进行疲劳寿命预测,得到立柱各部分的疲劳寿命和安全系数,并比较焊缝坡口类型和角度对立柱疲劳寿命的影响。
通过双伸缩立柱的仿真分析,得到了不同焊缝结构、工况条件下双伸缩立柱的应力和疲劳寿命,为液压支架立柱的设计和使用提供了理论依据。论文在UG环境下生成焊缝的方法和利用ANSYS耦合节点自由度模拟焊接连接的方法,为其它工程焊接件的仿真提供了方法和依据。
Column is one of the main bearing structure in hydraulic support, its strength and fatigue life plays a vital role to safety production in coal mine. For hydraulic support column the to improve the service life of the pillar with its working reliability and important meaning.It is of extremely important meaning to proceed stress analysis and fatigue life prediction of hydraulic support's column. Now, the stress analysis and fatigue life prediction of double-telescopic props are proceeded by relying on experience or theoretical calculation, the result accuracy is poor. The stress analysis and fatigue life prediction proceeded by the computer simulation technology can help to reduce development costs, shorten the development cycle and improve reliability level.
The failure forms and failure mechanism of double-telescopic props are analyzed through collecting material and put forward that weld fatigue failure is the main failure forms of column. In accordance with the standards MT313-1992 "technology conditions of hydraulic support column", stress of double-telescopic props with 1.5 times axial load and eccentric loads 1.1 times are tested; The entity model and finite element model are built by using UG modeling software and ANSYS finite element analysis software; In the same conditions of loading, the finite element analysis are done; The reliability of finite element analysis are verified by comparing test results and finite element analysis results.
The research is preceeded based on the weld structure of double-telescopic props in this paper. Stress analysis are done from two aspects:test and simulation, and to stress analysis results for load process the fatigue life are predicted by using the method of local stress strain gauge. And the influence of weld structure and stress concentration to double-telescopic props strength is considered.Last, on the basic of s-n curve and load spectrum curve, the fatigue life prediction of double-telescopic props with different weld structure are proceeded by using method of local stress strain gauge through ANSYS/FE-SAFE fatigue module to get of fatigue life and safety coefficient on each part of double-telescopic props and compare the influence to fatigue life of double-telescopic props brought by weld groove type and angle to get fatigue life and safety coefficient on each part of column and compare the influence to fatigue life of column brought by weld groove type and angle.
The stress and fatigue life of double-telescopic under different weld structure and working condition are obtained through the simulation and analysis, which can provide theoretical basis for the design and use of double-telescopic props.The method on weld generation in UG environment and the simulation way on welding connection through coupling freedom of nodes in ANSYS are also introduced in this paper,who can provide method and basis for other engineering simulation.
引文
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[12]高郁,冯昊.我国液压支架技术现状及发展[J].煤炭技术,2003,22(7)：4-6.
[13]王国法.新型液压支架及液压支架技术发展方向[J].煤炭科学技术,2002,3.
[14]陈铁军,李忠平,王亚军.关于DBT液压支架立柱端口密封的改进[J].液压气动与密封,2007,6：38-39.
[15]李武,鲍传余,陶峥.ZY4000/19/37型液压支架的故障分析[J].煤矿机电,2002,5：28-29.
[16]陈渊,马宏伟.煤矿液压缸环焊缝缺陷超声成像检测系统的研制[J].无损检测,2009,31(9)：715-718.
[17]Chen Yuan, Ma Hongwei. Study on Ultrasonic Imaging Testing Technique of Angle Probe for Girth Weld of Hydraulic Cylinder Used in Coal Mine[C].2009 International Conference on Measuring Technology and Mechatronics Automation(ICMTMA 2009), Zhangjiajie, Apr.11-12,2009,57-60.
[18]王胜.双周疲劳载荷下焊接接头的疲劳行为[D].天津：天津大学,2008.
[19]陈伯蠡.焊接工程缺欠分析与对策[M].北京：机械工业出版社,1999.
[20]张敏强.焊接结构疲劳寿命评估问题的研究[D].大连：大连理工大学,2005.
[21]李进荣.液压支架立柱柱头失效原因分析[J].机械管理开发,2006,3：70-71.
[22]周玉亮.液压支架双伸缩立柱失效形式的研究与分析[J].2009,30(12)：68-70.
[23]文建国,张志民,党铁果.ZY4000/14/32型掩护式液压支架损坏情况分析及修复[J]煤炭技术,2002,21(10).
[24]郑秀援.应力应变电测技术[M],第1版.北京：国防工业出版社,1995.
[25刘明亮,高文华.应变化偏位误差的分析[J].佳木斯工学院学报,1996,14(1)：62-65.
[26]郑大素,杨淳,曲维波.直角应变化固有测量误差分析及贴片定位研究[J].烟台大学学报(自然科学与工程版),1997,10(2)：126-130.
[27]颜京磊.变压器油箱建模、分析和测试[D].济南：山东大学,2008.
[28]康鲁杰,杨继红.电阻应变片的选用[J].衡器,2004,33(6)：9-10.
[29]Margrit Hanbucken and Jean-Paul Deville. Stess and Strain in Epitaxy:The Oretical Concepts, Measurements and APPlications. Jul,2001.
[29]李蓉.液压支架报废技术检验规范的研究[D].太原：太原理工大学,2008.
[30]MT 313-1992,液压支架立柱技术条件[S].北京：中华人民共和国能源部,1992.
[31]王美娜,肖兴明,徐波等.液压支架立柱试验台测控系统的研究与设计[J].煤炭工程,2008,11：78-79.
[32]王国法,蒲宝山.《液压支架通用技术条件》修订对设计的影响[J].煤炭学报.2002,4：434-439.
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