机车构架侧梁焊接数值仿真与变形控制
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摘要
构架是机车车辆的重要承载部件,其侧梁的焊接残余变形是影响构架生产质量的关键因素。因此,定量地预测焊接变形规律,并在此基础上实现最优控制,不仅对构架,而且对其它焊接构件的完整性设计和制造工艺方法的选择以及运行中的安全评定具有重要的理论价值与工程意义。
本文首先利用热弹塑性耦合法和固有应变法分别对侧梁模型进行了焊接数值仿真,并与实验测量结果进行了对比验证；在此基础上对控制焊接变形的工艺参数进行了一系列深入研究,得到最优的焊接工艺控制参数。本文的研究工作及研究成果主要有：
1.修正了固有应变法。以T形焊接接头为算例,结合热弹塑性有限元法和映射应变分量法研究角焊缝角变形的产生机制,认为固有剪切应变才是产生角变形的主要根源。以此观点为基础,通过数值仿真和实验,对比分析了两种不同的加载方位对横向约束度、横向固有应变及残余角变形的影响,研究结果表明沿焊缝表面斜向加载更接近于实际测量值和热弹塑性模拟值。
2.建立侧梁三维数值分析模型,根据实际焊接参数、焊接顺序对数值模型进行加载计算,得到整个焊接过程的瞬态温度场；然后以此温度场为基础,对侧梁分别进行了热弹塑性耦合数值分析和基于固有应变法的焊接残余变形分析,这两种仿真值与测量值对比表明外部4条纵向焊缝是造成侧梁焊接残余变形的主要因素,且三者变形规律基本吻合,热弹塑性数值仿真结果与测量值间的误差较小,在10%以内。
3.以热弹塑性仿真模型为基础,优化分析了外部4条纵向焊缝的焊接顺序与方向对焊接变形的影响规律。为了能够对焊接顺序和方向这样的“非变量”进行优化分析,借鉴C语言编程中指针和堆栈的概念,生成所有的排序组合,通过对指针变量的分析实现对焊接顺序和方向的优化。
4.提取以指针变量为基础所得到的优化分析结果中的可行方案,利用正交试验法,形成四因素三水平的正交试验表。通过正交试验分析,得出各因素对焊接残余变形影响的主次顺序和最优方案。研究结果表明打底层和盖面层的焊接顺序在焊接变形中起重要作用,为主要因素。对于立弯和旁弯分别得到不同的“最优”方案,综合分析后确定了一个最优方案,优化后侧梁的立弯降低18.9%,旁弯降低9.5%。
5.由于侧梁非严格对称,且外部4条主焊缝环绕在纵向中性轴(X轴)的四个角点；焊缝金属收缩是形成焊接残余变形的主要因素。因此提出了每条主焊缝焊接时的反变形面压力大小及方向都互不相同的逐一反变形法。通过综合分析、评估,确定了最优方案,其立弯量为+4.87mm,与无反变形压力时的立弯量+6.18mm相比,降低了21%；其旁弯量为+10.34mm,与无反变形压力时的旁弯量-10.78mm相比,除量值有所降低外,弯曲方向也发生了改变,与内部焊缝的焊接残余变形方向相反。
6.以平板对接焊为例,对动态温差拉伸法(DC-LSND法)作用下的焊接变形进行了数值分析,并与实验对比,结果表明实验与数值仿真结果较吻合,通过此工艺能够得到低应力小变形的焊接效果。
7.热沉强度h及热沉热源距离L是影响焊接应力和变形控制效果的主要参数,以T形单斜坡口焊接梁为例,通过优化分析得到最优的h、L值,与常规焊相比,其Y向位移降低了43.7%,Z向位移降低了47.0%。通过对比正交试验表中的极差值表明热沉强度h在DC-LSND焊中起主要作用,而热沉热源距离L为次要因素。经分析计算,分别得到位移值δ和μ(分别为横向和垂向)随热沉参数h、L的变化曲线,由此推荐热沉强度h的最佳取值范围为[0.004,0.2]W/mm2K,热沉热源距离L的最佳取值范围为[15,30]mm。
8.为进一步控制侧梁的焊接残余变形,本文研究了焊接方向,顺序,反变形等综合措施作用下的侧梁焊接变形规律。在考虑内部焊缝焊接残余变形量及方向的情况下,当控制措施联合作用时,所有焊缝焊接完毕后侧梁中部弯曲变形量及方向：δ为+2.64mm；μ为+1.46mm。与无任何控制措施时的变形相比,旁弯δ量值降低了84.0%,立弯μ量值降低了73.8%,侧梁中部用于评判弯曲的节点平均位移值小于3mm。
The bogie frame is the main carrying part of locomotive, the welding residual deformation of the side beam is the key factors effecting production quality. So the quantitative predicting of welding deformation regularities and, thereon, taking the optimal quality-control measures, have theoretical values and engineering significance in the integral design, manufacturing technique selection and the service security evaluation of the side beam welding structures themselves, as well as other kinds of welding structures.
In this dissertation, first, based on thermal elastic-plastic coupling method and inherent strain method, the welding residual deformation's numerical simulation was done respectively for the side beam model, and compared with experimental measurement result. Then, on this basis, for the process parameters of controlling welding deformation, a series of investigations were made, optimal process parameters have been got by optimization analysis. The study works and achievements are summed up as follows:
1. The inherent strain method has been corrected. Take a welded T-joint as example, the formation mechanism of fillet weld's angle distortion was studied by combining thermal elastic plastic analysis with mapping strain component method. The results show that the main source of fillet weld's angle distortion is the inherent shear strain but not the transverse inherent normal strain. Then, based on the view, two different loading direction that influence transverse restraint degree、transverse inherent strain and residual angle distortion were analyzed. The result made by the diagonal load along weld's surface is closer to the practical measured values and thermal-elastic-plastic simulated values, it indicate the rationality of the diagonal loading along weld's surface.
2. The three-dimensional numerical analysis model was established. According to the establishment current welding parameters and sequence, The numerical model was loaded and analyzed, and transient temperature field throughout the welding process was got. Based on the transient temperature field, thermal elastic-plastic coupling numerical analysis has been done, and welding residual deformation analysis using inherent strain method has been made also. To validate the fitness of two simulation methods, the actual welding deformations are measured after experimental side beam welded, and by contrasting simulation value with measured value, it was found that the main factor of the side beam welding residual deformation is the external four longitudinal weld, deformation law of three results are consistent with each other; the error between the result of thermal elastic-plastic coupling analysis and measured value is less, within10%.
3. Based on the thermal elastic-plastic simulation method, the laws of welding deformation caused by the welding sequence and direction of the external four longitudinal weld were analyzed by optimization method. In order to optimize the welding sequence and direction(nonnumeric variable), the concept of pointer and stack of C language programming were referenced, the combination and order were generated, saved them in the array, therefore, the optimization analysis of pointer variable was equated with the optimization analysis of welding sequence and direction.
4. Based on orthogonal test, the schemes obtained by pre-analysis were extracted, then, the datas formed orthogonal experiment table comprising four-factor three-level. Through the orthogonal-test analysis, the important order of the various factors effecting residual welding deformation is found, as well as optimum scheme. The welding sequence of the first layer and the second layer play an important roles on the welding residual deformation, and is the main factors of the welding residual deformation. The different "optimum" schemes of vertical bending and side bengding were respectively obtained, after comprehensive analysis the optimum scheme was determined. The optimum scheme can make vertical bend deformation reduce about18.9%, and make lateral bend deformation reduce about9.5%.
5. Because the side beam is asymmetric, and the external four longitudinal weld locate four corner of longitudinal neutral axis(X axis) of the side beam. For the groove weldment, the shrinkage of weld metal is the main factor making residual welding deformation. Based on analysis above, when the main welds were welded, it was supposed that surface pressure value and direction of the reverse-deformation were different each other.Compared with the reverse-deformation method of the uniform surface pressure value and direction, the new method is called as one by one reverse deformation method. Through comprehensive analysis and evaluation, it was determined that the twenty-ninth scheme of the optimizing sequence is as the optimum scheme. The vertical bending value of the optimum scheme is+4.87mm, compare with+6.18mm of the vertical bending value without reversible deformation pressure, the quantity value is decreased by21%, and the side bengding value is+10.34mm, compare with-10.78mm of the side bengding value without reversible deformation pressure, the quantity value is slightly decreased, and it is important that the bending direction is changed, the opposite direction with the welding residual deformation of the intenal welds.
6. Butt plates welding was as an example, the DC-LSND numerical simulation was done, then,test-part was measured, the computation result was founded basically consistent with the measured data, therefore, through process control, the welding effect of low stress no-distortion can be obtained.
7. The L of the distance between arc and heat sink is one of main parameter influencing the control effect, as well as the h of the heat sink intensity. With T-shape single slope groove welding beam as an example, the optimal value about h、L were acquired by the optimization analysis. Compare the result of the DC-LSND welding's optimum scheme with the result of conventional welding, because of the action of heat sink, the displacement of Y-direction is decreased by43.7%, the displacement of Z-direction is decreased by47.0%. Compare with the difference of the orthogonal experiment table, it is indicate that the h of the heat sink intensity plays a major role, whereas the L of the distance between arc and heat sink is the secondary factor. Through analysis and calculation, the change curves that δ (transverse displacement)and μ (vertical displacement)of the displacement value was variational with the parameters changing of the heat sink have been respectively gotten. Based on the change curves, the best range of the h is [0.004,0.2] W/mm2K, the best range of the L is [15,30]mm.
8. For controlling the welding residual deformation of the side beam, the welding deformation law by the combined effect with the welding sequence and direction and the reverse-deformation is researched. When the welding residual deformation caused by Internal welds was been calculated in advance, together with the combined effect of optimal parameters, after all welds were been welded, the amount and direction of the welding residual transverse displacement δ in middle part of side beam is+2.64mm, and vertical displacement μ is+1.46mm. Compared with the welding residual displacement withou control measures, it can make lateral bend deformation reduce about84%,and make vertical bend deformation reduce about73.8%, and make bending direction change. And, the node average displacement evaluating bend in middle part of side beam is less than3mm.
本文首先利用热弹塑性耦合法和固有应变法分别对侧梁模型进行了焊接数值仿真,并与实验测量结果进行了对比验证；在此基础上对控制焊接变形的工艺参数进行了一系列深入研究,得到最优的焊接工艺控制参数。本文的研究工作及研究成果主要有：
1.修正了固有应变法。以T形焊接接头为算例,结合热弹塑性有限元法和映射应变分量法研究角焊缝角变形的产生机制,认为固有剪切应变才是产生角变形的主要根源。以此观点为基础,通过数值仿真和实验,对比分析了两种不同的加载方位对横向约束度、横向固有应变及残余角变形的影响,研究结果表明沿焊缝表面斜向加载更接近于实际测量值和热弹塑性模拟值。
2.建立侧梁三维数值分析模型,根据实际焊接参数、焊接顺序对数值模型进行加载计算,得到整个焊接过程的瞬态温度场；然后以此温度场为基础,对侧梁分别进行了热弹塑性耦合数值分析和基于固有应变法的焊接残余变形分析,这两种仿真值与测量值对比表明外部4条纵向焊缝是造成侧梁焊接残余变形的主要因素,且三者变形规律基本吻合,热弹塑性数值仿真结果与测量值间的误差较小,在10%以内。
3.以热弹塑性仿真模型为基础,优化分析了外部4条纵向焊缝的焊接顺序与方向对焊接变形的影响规律。为了能够对焊接顺序和方向这样的“非变量”进行优化分析,借鉴C语言编程中指针和堆栈的概念,生成所有的排序组合,通过对指针变量的分析实现对焊接顺序和方向的优化。
4.提取以指针变量为基础所得到的优化分析结果中的可行方案,利用正交试验法,形成四因素三水平的正交试验表。通过正交试验分析,得出各因素对焊接残余变形影响的主次顺序和最优方案。研究结果表明打底层和盖面层的焊接顺序在焊接变形中起重要作用,为主要因素。对于立弯和旁弯分别得到不同的“最优”方案,综合分析后确定了一个最优方案,优化后侧梁的立弯降低18.9%,旁弯降低9.5%。
5.由于侧梁非严格对称,且外部4条主焊缝环绕在纵向中性轴(X轴)的四个角点；焊缝金属收缩是形成焊接残余变形的主要因素。因此提出了每条主焊缝焊接时的反变形面压力大小及方向都互不相同的逐一反变形法。通过综合分析、评估,确定了最优方案,其立弯量为+4.87mm,与无反变形压力时的立弯量+6.18mm相比,降低了21%；其旁弯量为+10.34mm,与无反变形压力时的旁弯量-10.78mm相比,除量值有所降低外,弯曲方向也发生了改变,与内部焊缝的焊接残余变形方向相反。
6.以平板对接焊为例,对动态温差拉伸法(DC-LSND法)作用下的焊接变形进行了数值分析,并与实验对比,结果表明实验与数值仿真结果较吻合,通过此工艺能够得到低应力小变形的焊接效果。
7.热沉强度h及热沉热源距离L是影响焊接应力和变形控制效果的主要参数,以T形单斜坡口焊接梁为例,通过优化分析得到最优的h、L值,与常规焊相比,其Y向位移降低了43.7%,Z向位移降低了47.0%。通过对比正交试验表中的极差值表明热沉强度h在DC-LSND焊中起主要作用,而热沉热源距离L为次要因素。经分析计算,分别得到位移值δ和μ(分别为横向和垂向)随热沉参数h、L的变化曲线,由此推荐热沉强度h的最佳取值范围为[0.004,0.2]W/mm2K,热沉热源距离L的最佳取值范围为[15,30]mm。
8.为进一步控制侧梁的焊接残余变形,本文研究了焊接方向,顺序,反变形等综合措施作用下的侧梁焊接变形规律。在考虑内部焊缝焊接残余变形量及方向的情况下,当控制措施联合作用时,所有焊缝焊接完毕后侧梁中部弯曲变形量及方向：δ为+2.64mm；μ为+1.46mm。与无任何控制措施时的变形相比,旁弯δ量值降低了84.0%,立弯μ量值降低了73.8%,侧梁中部用于评判弯曲的节点平均位移值小于3mm。
The bogie frame is the main carrying part of locomotive, the welding residual deformation of the side beam is the key factors effecting production quality. So the quantitative predicting of welding deformation regularities and, thereon, taking the optimal quality-control measures, have theoretical values and engineering significance in the integral design, manufacturing technique selection and the service security evaluation of the side beam welding structures themselves, as well as other kinds of welding structures.
In this dissertation, first, based on thermal elastic-plastic coupling method and inherent strain method, the welding residual deformation's numerical simulation was done respectively for the side beam model, and compared with experimental measurement result. Then, on this basis, for the process parameters of controlling welding deformation, a series of investigations were made, optimal process parameters have been got by optimization analysis. The study works and achievements are summed up as follows:
1. The inherent strain method has been corrected. Take a welded T-joint as example, the formation mechanism of fillet weld's angle distortion was studied by combining thermal elastic plastic analysis with mapping strain component method. The results show that the main source of fillet weld's angle distortion is the inherent shear strain but not the transverse inherent normal strain. Then, based on the view, two different loading direction that influence transverse restraint degree、transverse inherent strain and residual angle distortion were analyzed. The result made by the diagonal load along weld's surface is closer to the practical measured values and thermal-elastic-plastic simulated values, it indicate the rationality of the diagonal loading along weld's surface.
2. The three-dimensional numerical analysis model was established. According to the establishment current welding parameters and sequence, The numerical model was loaded and analyzed, and transient temperature field throughout the welding process was got. Based on the transient temperature field, thermal elastic-plastic coupling numerical analysis has been done, and welding residual deformation analysis using inherent strain method has been made also. To validate the fitness of two simulation methods, the actual welding deformations are measured after experimental side beam welded, and by contrasting simulation value with measured value, it was found that the main factor of the side beam welding residual deformation is the external four longitudinal weld, deformation law of three results are consistent with each other; the error between the result of thermal elastic-plastic coupling analysis and measured value is less, within10%.
3. Based on the thermal elastic-plastic simulation method, the laws of welding deformation caused by the welding sequence and direction of the external four longitudinal weld were analyzed by optimization method. In order to optimize the welding sequence and direction(nonnumeric variable), the concept of pointer and stack of C language programming were referenced, the combination and order were generated, saved them in the array, therefore, the optimization analysis of pointer variable was equated with the optimization analysis of welding sequence and direction.
4. Based on orthogonal test, the schemes obtained by pre-analysis were extracted, then, the datas formed orthogonal experiment table comprising four-factor three-level. Through the orthogonal-test analysis, the important order of the various factors effecting residual welding deformation is found, as well as optimum scheme. The welding sequence of the first layer and the second layer play an important roles on the welding residual deformation, and is the main factors of the welding residual deformation. The different "optimum" schemes of vertical bending and side bengding were respectively obtained, after comprehensive analysis the optimum scheme was determined. The optimum scheme can make vertical bend deformation reduce about18.9%, and make lateral bend deformation reduce about9.5%.
5. Because the side beam is asymmetric, and the external four longitudinal weld locate four corner of longitudinal neutral axis(X axis) of the side beam. For the groove weldment, the shrinkage of weld metal is the main factor making residual welding deformation. Based on analysis above, when the main welds were welded, it was supposed that surface pressure value and direction of the reverse-deformation were different each other.Compared with the reverse-deformation method of the uniform surface pressure value and direction, the new method is called as one by one reverse deformation method. Through comprehensive analysis and evaluation, it was determined that the twenty-ninth scheme of the optimizing sequence is as the optimum scheme. The vertical bending value of the optimum scheme is+4.87mm, compare with+6.18mm of the vertical bending value without reversible deformation pressure, the quantity value is decreased by21%, and the side bengding value is+10.34mm, compare with-10.78mm of the side bengding value without reversible deformation pressure, the quantity value is slightly decreased, and it is important that the bending direction is changed, the opposite direction with the welding residual deformation of the intenal welds.
6. Butt plates welding was as an example, the DC-LSND numerical simulation was done, then,test-part was measured, the computation result was founded basically consistent with the measured data, therefore, through process control, the welding effect of low stress no-distortion can be obtained.
7. The L of the distance between arc and heat sink is one of main parameter influencing the control effect, as well as the h of the heat sink intensity. With T-shape single slope groove welding beam as an example, the optimal value about h、L were acquired by the optimization analysis. Compare the result of the DC-LSND welding's optimum scheme with the result of conventional welding, because of the action of heat sink, the displacement of Y-direction is decreased by43.7%, the displacement of Z-direction is decreased by47.0%. Compare with the difference of the orthogonal experiment table, it is indicate that the h of the heat sink intensity plays a major role, whereas the L of the distance between arc and heat sink is the secondary factor. Through analysis and calculation, the change curves that δ (transverse displacement)and μ (vertical displacement)of the displacement value was variational with the parameters changing of the heat sink have been respectively gotten. Based on the change curves, the best range of the h is [0.004,0.2] W/mm2K, the best range of the L is [15,30]mm.
8. For controlling the welding residual deformation of the side beam, the welding deformation law by the combined effect with the welding sequence and direction and the reverse-deformation is researched. When the welding residual deformation caused by Internal welds was been calculated in advance, together with the combined effect of optimal parameters, after all welds were been welded, the amount and direction of the welding residual transverse displacement δ in middle part of side beam is+2.64mm, and vertical displacement μ is+1.46mm. Compared with the welding residual displacement withou control measures, it can make lateral bend deformation reduce about84%,and make vertical bend deformation reduce about73.8%, and make bending direction change. And, the node average displacement evaluating bend in middle part of side beam is less than3mm.
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