起重机运行机构底座处裂纹形成的原因与对策研究
摘要
起重运输机械作为物料搬运、装卸或用于安装的机械设备,已经由为各生产部门服务的辅助设备发展为实现生产机械化和自动化不可或缺的设备。其运行状态的好坏极大地影响着企业的生产效率,对实现安全生产也至关重要。因此,对起重机故障的分析有着重要的实际意义。
本文以武钢冷轧厂0号桥式起重机为对象,以大车运行机构底座处下盖板裂纹为研究内容,运用力学知识和基本原理对裂纹形成的机理进行了分析,通过模态分析和瞬态动力学分析,重点研究了该起重机运行机构处下盖板裂纹产生的机理。本文主要进行了以下研究:
首先,对主梁进行静强度分析,通过起重机工作载荷与运行机构底座处裂纹形成关系的研究,推断出该起重机运行机构底座处下盖板开裂的原因是由于局部设计不合理造成的。
其次,本文对主梁进行了模态分析,研究了主梁的振动特性以及运行机构底座处下盖板在振动的影响下,产生裂纹的可能性。
随后,本文运用瞬态动力学对运行机构底座处下盖板裂纹产生的机理进行了深入研究,并结合模态分析的结果,找出了裂纹产生的根本原因,提出了相应的修复改进措施,同时对改进措施进行了分析。
本文的所有理论分析工作都是运用大型有限元分析软件ANSYS完成的,在分析过程中,无论是对该起重机的有限元建模,还是静强度分析与动力学分析,都大量应用APDL语言,并进行了二次开发,使得模型建立的参数化和加载过程的自动化水平得到大大提升,提高了分析效率。
本文所做的研究工作,对起重机的设计、制造和维护,以及准确评估起重机的运行性能等方面都具有较大的指导意义。
Material handling machinery is a machinery equipment which servered as material carrying, loading and unloading or used to install, it becomes from the assistant equipment of the manufacture department to the indispensable installation of manufacture mechanization and automation. it's condition greatly affects business production efficiency, It is also utmost importance to achieves the safe production. Hence, it has significant actual sense to analysis the malfunction of crane.The paper puts the WuGang cold roll mill crane of 0 as target, the crack of lap cover board of the traveling mechanism of the large traveler as research contents, applies the information of mechanics and basic principle to analyse the mechanism that takes shape to the crackle, the analysis stress is researched the mechanism that the crane crackle come into being by means of dynamics analysis and vibration mode. It chiefly carries on such researches:First of all, carry on the statics analysis to the girder, conclude that the crane fault was caused by local fault, Moreover, do some research on the relationship between the crane work loading and the influence of crackle takes shape on the traveling organization pedestal.Secondly, carry on the mode analysis to the girder, research the girder vibration property and the probability of crackle takes shape in the vibration effects of traveling organization pedestal.Thirdly, carry on thoroughly researching about the mechanism of crackle takes shape on the travelling organization pedestal with instantaneous dynamics, and unite the mode analysis result, find out the fundamental reason that the crackle takes shape, supply the theory sustain to the repair of traveling crane.Finally, utilize the large finite element analysis software ANSYS, Carry on the finite element model building and analysis calculation to the tavelling crane girder. Utilize APDL language to carry on parameterization model building and loading in this process, and analysis the techniques about the model simplifying. On the basis of the research, it has greate direction sense to the crane design, manufacture and maintain, and also to the accurately assess the crane operational performance and so on.
本文以武钢冷轧厂0号桥式起重机为对象,以大车运行机构底座处下盖板裂纹为研究内容,运用力学知识和基本原理对裂纹形成的机理进行了分析,通过模态分析和瞬态动力学分析,重点研究了该起重机运行机构处下盖板裂纹产生的机理。本文主要进行了以下研究:
首先,对主梁进行静强度分析,通过起重机工作载荷与运行机构底座处裂纹形成关系的研究,推断出该起重机运行机构底座处下盖板开裂的原因是由于局部设计不合理造成的。
其次,本文对主梁进行了模态分析,研究了主梁的振动特性以及运行机构底座处下盖板在振动的影响下,产生裂纹的可能性。
随后,本文运用瞬态动力学对运行机构底座处下盖板裂纹产生的机理进行了深入研究,并结合模态分析的结果,找出了裂纹产生的根本原因,提出了相应的修复改进措施,同时对改进措施进行了分析。
本文的所有理论分析工作都是运用大型有限元分析软件ANSYS完成的,在分析过程中,无论是对该起重机的有限元建模,还是静强度分析与动力学分析,都大量应用APDL语言,并进行了二次开发,使得模型建立的参数化和加载过程的自动化水平得到大大提升,提高了分析效率。
本文所做的研究工作,对起重机的设计、制造和维护,以及准确评估起重机的运行性能等方面都具有较大的指导意义。
Material handling machinery is a machinery equipment which servered as material carrying, loading and unloading or used to install, it becomes from the assistant equipment of the manufacture department to the indispensable installation of manufacture mechanization and automation. it's condition greatly affects business production efficiency, It is also utmost importance to achieves the safe production. Hence, it has significant actual sense to analysis the malfunction of crane.The paper puts the WuGang cold roll mill crane of 0 as target, the crack of lap cover board of the traveling mechanism of the large traveler as research contents, applies the information of mechanics and basic principle to analyse the mechanism that takes shape to the crackle, the analysis stress is researched the mechanism that the crane crackle come into being by means of dynamics analysis and vibration mode. It chiefly carries on such researches:First of all, carry on the statics analysis to the girder, conclude that the crane fault was caused by local fault, Moreover, do some research on the relationship between the crane work loading and the influence of crackle takes shape on the traveling organization pedestal.Secondly, carry on the mode analysis to the girder, research the girder vibration property and the probability of crackle takes shape in the vibration effects of traveling organization pedestal.Thirdly, carry on thoroughly researching about the mechanism of crackle takes shape on the travelling organization pedestal with instantaneous dynamics, and unite the mode analysis result, find out the fundamental reason that the crackle takes shape, supply the theory sustain to the repair of traveling crane.Finally, utilize the large finite element analysis software ANSYS, Carry on the finite element model building and analysis calculation to the tavelling crane girder. Utilize APDL language to carry on parameterization model building and loading in this process, and analysis the techniques about the model simplifying. On the basis of the research, it has greate direction sense to the crane design, manufacture and maintain, and also to the accurately assess the crane operational performance and so on.
引文
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[16] 马宵.利用ANSYS分析悬臂起重机金属结构的应力.起重运输机械.2004(5)
[17] 陈精一,蔡国忠.电脑辅助工程分析ANSYS使用指南.铁道出版社.2001
[18] 陈安华,刘德顺等.振动诊断的动力学理论与方法.机械工业出版社.2002
[19] 博弈创作室.APDL参数化有限元分析技术及其应用实例.中国水利出版社.2004
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[23] 过玉卿.起重运输机械.华中理工大学出版社.1992
[24] 王彬.振动分析及应用.海潮出版社.1992
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[28] 黄义.弹性力学基础及有限单无法.冶金工业出版社.1983
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[30] J.罗克,W.C.杨.应力应变公式.中国建筑工业出版社.1985
[31] S.铁摩辛柯,D.H.杨.工程的振动问题.人民铁道出版社,1978
[32] M. F. Kanninen 等. Probailistic Modals of Culmulative Damage. john Wiley, New Youk. 1985
[33] L. D. Lutes等. Improved Spectral Method for Variable Amplitude Fatigue Prediction.j.Struct.Div.ASCE, vol.116,NO.4.1990
[34] 傅志方.振动模态分析与参数识别.机械工业出版社.1990
[35] 张安哥. The Overload Retarrdation Effect in Fatigue Crack Propation of WGCI.J.ofEngng.Mat &Tech.Vol 113.No.3:307-313, 1991
[36] 林茂松等.焊接构件疲劳可靠度的计算.起重运输机械.2000(3)
[37] 程文明,王金诺.门式起重机结构参数与动态指标耦合关系.西南交通大学学报.2002年12月
[38] O. C. Zienkiewicz. The finite element method. 4th,1987. McGRAW- HILL BOOK COMPANY
[39] 沃德.海伦.模态分析理论与试验.北京理工大学出版社.2001
[40] S.G凯利.机械振动.科学出版社.2002
[41] 崔忠健.抓斗龙门起重机金属结构开裂的处理方法.港口机械.2002(1)
[42] 李英杰等.20t天车主梁裂纹分析与处理.山西冶金.2004(2)
[43] 张质文,虞和谦.起重机设计手册.中国铁道出版社.2001
[44] 顾迪民.起重机事故分析及对策.人民交通出版社.2001
[45] ANSYS结构分析指南(下).Swanson Analysis System.inc. 1998
[46] 曹仁政.机械零件.冶金工业出版社.1985
[47] 廖伯瑜.机械故障诊断基础.冶金工业出版社.2002
[48] 殷成凤.门座起重机人字架有限元分析.建设机械技术与管.2001年11月p24-25
[49] 丁晓红.起重机车轮的疲劳可靠性分析.起重运输机械.1999(3)
[50] 董达善,石来德.起重机承轨梁水平裂纹成因分析.同济大学学报.2001年12月
[51] 荣国瑞.汽车起重机车架强度分析的新方法.重庆建筑大学学报.2000年8月第22卷第4期
[52] 李英杰等.20t天车主梁裂纹分析与处理.山西冶金.2004(2)
[53] 薛继忠,易传云.桥式起重机桥架结构的三维有限元分析.机械与电子.2004(8)p12-15
[54] 林茂松,张晖.桥式起重机主梁应力幅的数值计算.西南工学院学报 第14卷第31期1999年9月
[55] 徐水春,王者静.塔式起重机结构件安全寿命评估.建筑机械.2003(11)p54-55
[56] 龙沂.塔式起重机动态特性研究的现状与发展.建筑机械.1998(10)
[57] 胡胜修.铸造起重机主梁疲劳破坏的分析及对策.起重运输机械.1998(5)p22-24
[58] Van De Pas, Julius P. New fatigue provisions for the design of crane runway girders. Engineering Journal, v 39, n 2, Second Quarter, 2002, p 65-73
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[2] 张质文等.起重机设计手册.北京:中国铁道出版社.1998
[3] 张利英,赵昕哲,吴建松.ANSYS在塔式起重机结构分析中的应用.设计研究.2004(9),p57-59
[4] 郭建生,余红飞.DLQ25A轮胎式起重机底架结构开裂成因的应力分析.港口装卸.2000年第6期 p10-12
[5] 杨新华.大吨位桥式起重机主梁静刚度检测方法.工业安全与防尘.1998年第1期 p22-24
[6] 肖汉斌,徐长生.大型结构应变模态分析软件的应用研究.水利电力机械.1998年6月p20-23
[7] 邢静忠,王永岗等.ANSYS7.0分析实例与工程应用.机械工业出版社.2004
[8] 刘涛,杨凤鹏.精通ANSYS.清华大学出版社.2002
[9] ANSYS Basic Analysis Procedures Guide. Swanson Analysis System.inc. 1998
[10] ANSYS Element Reference. Swanson Analysis System.inc. 1998
[11] ANSYS Command Reference. Swanson Analysis System.inc. 1998
[12] ANSYS 高级分析指南. Swanson Analysis System.inc. 1998
[13] 王国强.实用工程模拟技术及其在ANSYS上的实践.西北工业大学出版社.2001
[14] 武江传.ANSYS在结构分析中的应用.连云港化工高等专科学校学报.2002(3)
[15] 覃丽坤.实测吊车梁变幅疲劳及振动模态分析.工业建筑.2004(5)
[16] 马宵.利用ANSYS分析悬臂起重机金属结构的应力.起重运输机械.2004(5)
[17] 陈精一,蔡国忠.电脑辅助工程分析ANSYS使用指南.铁道出版社.2001
[18] 陈安华,刘德顺等.振动诊断的动力学理论与方法.机械工业出版社.2002
[19] 博弈创作室.APDL参数化有限元分析技术及其应用实例.中国水利出版社.2004
[20] 陈花玲.机械工程测试技术.机械工业出版社.2002
[21] 皮萨林科.复杂应力状态下的材料变形与强度.科学出版社.1983
[22] 黄玉盈.结构振动分析基础.华中工学院出版社.1988
[23] 过玉卿.起重运输机械.华中理工大学出版社.1992
[24] 王彬.振动分析及应用.海潮出版社.1992
[25] 许本文,焦群英.机械振动与模态分析基础.机械工业出版社.1998
[26] 方同,薛璞.振动理论及应用.西北工业大学出版社.1998
[27] 彭培英,王立彬.工程机械金属结构疲劳可靠性分析的响应面法.机械.2004年第31卷第8期 p20-23
[28] 黄义.弹性力学基础及有限单无法.冶金工业出版社.1983
[29] 虞和济.韩庆大等.设备故障诊断工程.冶金工业出版社.2001
[30] J.罗克,W.C.杨.应力应变公式.中国建筑工业出版社.1985
[31] S.铁摩辛柯,D.H.杨.工程的振动问题.人民铁道出版社,1978
[32] M. F. Kanninen 等. Probailistic Modals of Culmulative Damage. john Wiley, New Youk. 1985
[33] L. D. Lutes等. Improved Spectral Method for Variable Amplitude Fatigue Prediction.j.Struct.Div.ASCE, vol.116,NO.4.1990
[34] 傅志方.振动模态分析与参数识别.机械工业出版社.1990
[35] 张安哥. The Overload Retarrdation Effect in Fatigue Crack Propation of WGCI.J.ofEngng.Mat &Tech.Vol 113.No.3:307-313, 1991
[36] 林茂松等.焊接构件疲劳可靠度的计算.起重运输机械.2000(3)
[37] 程文明,王金诺.门式起重机结构参数与动态指标耦合关系.西南交通大学学报.2002年12月
[38] O. C. Zienkiewicz. The finite element method. 4th,1987. McGRAW- HILL BOOK COMPANY
[39] 沃德.海伦.模态分析理论与试验.北京理工大学出版社.2001
[40] S.G凯利.机械振动.科学出版社.2002
[41] 崔忠健.抓斗龙门起重机金属结构开裂的处理方法.港口机械.2002(1)
[42] 李英杰等.20t天车主梁裂纹分析与处理.山西冶金.2004(2)
[43] 张质文,虞和谦.起重机设计手册.中国铁道出版社.2001
[44] 顾迪民.起重机事故分析及对策.人民交通出版社.2001
[45] ANSYS结构分析指南(下).Swanson Analysis System.inc. 1998
[46] 曹仁政.机械零件.冶金工业出版社.1985
[47] 廖伯瑜.机械故障诊断基础.冶金工业出版社.2002
[48] 殷成凤.门座起重机人字架有限元分析.建设机械技术与管.2001年11月p24-25
[49] 丁晓红.起重机车轮的疲劳可靠性分析.起重运输机械.1999(3)
[50] 董达善,石来德.起重机承轨梁水平裂纹成因分析.同济大学学报.2001年12月
[51] 荣国瑞.汽车起重机车架强度分析的新方法.重庆建筑大学学报.2000年8月第22卷第4期
[52] 李英杰等.20t天车主梁裂纹分析与处理.山西冶金.2004(2)
[53] 薛继忠,易传云.桥式起重机桥架结构的三维有限元分析.机械与电子.2004(8)p12-15
[54] 林茂松,张晖.桥式起重机主梁应力幅的数值计算.西南工学院学报 第14卷第31期1999年9月
[55] 徐水春,王者静.塔式起重机结构件安全寿命评估.建筑机械.2003(11)p54-55
[56] 龙沂.塔式起重机动态特性研究的现状与发展.建筑机械.1998(10)
[57] 胡胜修.铸造起重机主梁疲劳破坏的分析及对策.起重运输机械.1998(5)p22-24
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