采用并行技术计算厚板焊接应力及其分布规律
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摘要
焊接连接是钢结构连接的主要方法之一,而厚板焊接加工会引起接头局部不均匀的热塑性变形和相变,从而产生焊接残余应力。焊接残余应力会影响结构施工和使用全过程,因此在进行钢结构设计和施工之前应该合理估计和考虑焊接残余应力影响。
根据厚板焊接形式,考虑40mm厚板X形和V形坡口焊缝,利用有限元计算软件ANSYS分析焊缝残余应力的分布,采用内热源模型模拟温度场,将温度结果作为荷载施加到结构应力计算模型上,得到厚板残余应力的分布特征。
根据模拟结果可知:厚板焊缝处节点每次热源的经过都会形成一个峰值,并且焊缝有几道堆焊就有几个波峰;要给定材料各项物理性能参数随温度的变化值,才能得到准确的温度场;焊接表面上厚度方向残余应力值最小,纵向方向残余应力值最大,并且超过了材料本身的屈服强度,这是应力强化的结果;厚板在不同约束下,线约束下的残余应力要比面约束的明显小;在相同的条件下,X形焊缝残余应力要比V形焊缝的要小;厚板残余应力并行运算的时间与网络传输及计算机的配置有关系。
最后根据计算结果的对比分析,对厚板残余应力的分析和研究提出了一些建议性的意见,具有一定的实用价值。
Welding is a typical steel connection joint, but the Residual stress (RS) is produced by heterogeneous plastic deformations, thermal contractions and phase transformations are induced by the thickness plate manufacturing process. The RS affects the period of construction as well as the period of service. It is reasonable to consider the effects of RS before design and construction.
According to plate welding forms, analyzing RS distribution for 40 mm X, V thickness plate by FEM software (ANSYS), and simulating the temperaturefield distribution by inner heat source. Temperature is calculated at first. Then it is applied to the structural model as a load to calculate RS distribution.
Research shows that the temperature of nodes in the weld seams reach peak when heat source pass; give the changes value for the physical propertyparameters of the material as the temperature, then can achieve accurate thetemperature field; residual stress in the thickness direction is the minimum andresidual stress values in vertical direction is the largest, and more than the yield strength, this is the result of stress strengthened; in the different constraints,the residual stress under line constrains is less than under area constrains; in the same condition, Than the obvious constraints on the surface in same condition,residual stress of X seam is less than V seam; parallel computing time for thethickness residual stress is relative with network transmission and computersetting.
Finally, according to the results of comparative analysis, the thickness residual stress analysis and research provide some recommendations.
根据厚板焊接形式,考虑40mm厚板X形和V形坡口焊缝,利用有限元计算软件ANSYS分析焊缝残余应力的分布,采用内热源模型模拟温度场,将温度结果作为荷载施加到结构应力计算模型上,得到厚板残余应力的分布特征。
根据模拟结果可知:厚板焊缝处节点每次热源的经过都会形成一个峰值,并且焊缝有几道堆焊就有几个波峰;要给定材料各项物理性能参数随温度的变化值,才能得到准确的温度场;焊接表面上厚度方向残余应力值最小,纵向方向残余应力值最大,并且超过了材料本身的屈服强度,这是应力强化的结果;厚板在不同约束下,线约束下的残余应力要比面约束的明显小;在相同的条件下,X形焊缝残余应力要比V形焊缝的要小;厚板残余应力并行运算的时间与网络传输及计算机的配置有关系。
最后根据计算结果的对比分析,对厚板残余应力的分析和研究提出了一些建议性的意见,具有一定的实用价值。
Welding is a typical steel connection joint, but the Residual stress (RS) is produced by heterogeneous plastic deformations, thermal contractions and phase transformations are induced by the thickness plate manufacturing process. The RS affects the period of construction as well as the period of service. It is reasonable to consider the effects of RS before design and construction.
According to plate welding forms, analyzing RS distribution for 40 mm X, V thickness plate by FEM software (ANSYS), and simulating the temperaturefield distribution by inner heat source. Temperature is calculated at first. Then it is applied to the structural model as a load to calculate RS distribution.
Research shows that the temperature of nodes in the weld seams reach peak when heat source pass; give the changes value for the physical propertyparameters of the material as the temperature, then can achieve accurate thetemperature field; residual stress in the thickness direction is the minimum andresidual stress values in vertical direction is the largest, and more than the yield strength, this is the result of stress strengthened; in the different constraints,the residual stress under line constrains is less than under area constrains; in the same condition, Than the obvious constraints on the surface in same condition,residual stress of X seam is less than V seam; parallel computing time for thethickness residual stress is relative with network transmission and computersetting.
Finally, according to the results of comparative analysis, the thickness residual stress analysis and research provide some recommendations.
引文
1拉达伊.焊接热效应.熊第京等译.北京:机械工业出版社, 1991:1-87
2 Lindgren L. E, Runnewalm H, Nasstron M. O. Simulation of Multi-pass Melding of a Thick plate. International Journal for Numerical Methods in Engineering, 1999, 44(9): 1301-1316
3 Zhao H. Y, Lu A. L, Shi Q. Y, etc al. Simulation of Welding Process of T-joints. Atca Metallurgical Sinica (English Letter), 2000, 13(1): 205-212
4 Xu Qinghong, Guo Wei , Tian Xiyang, etc al. Establishment and Verification of 3D temper ature Field Numerical Model. Transaction of the China Welding Institution, 1997, 8(2): 34-39
5 Karlsson R. I, Josefson B. L. Three-dimensional Finite Element Analysis of Temperature and Stresses in a Single-pass Butt-welded Pipe. ASME Journal of Pressure Vessel Techno logy, 1990, 112(2): 76-84
6 Eiji Takahash, Kenji Wai, Kunihiko Satoh. A Method of Measuring Triaxial Residual Stress in Heavy Section Butt Weldments. Trans of Japan Welding Society, 1997, 10(1): 36-45
7熊建民等.厚板焊接中残余应力的分布规律.湖北工学院学报, 1997, 9(2): 56-78
8王继峰.焊接温度场和应力场的热源模型研究. [燕山大学硕士论文]. 2006: 32-33
9 P. Dong, F. W. Brust. Welding Residual Stresses and Effects on Fracture in Pressure Vessel and Piping Components: A Millennium Review and Beyond. Journal of Pressure Vessel Technology, 2000, 122(3): 329-338
10 Kamichika, Ryoich, Yada, etc al. Internal Stresses in Thick Plates Weld-overlaid with Austenitic Stainless Steel EMDASH2. Transactions of the Japan Welding Society, 1974, 5(1): 22-31
11 Friedman. Thermomechanical Analysis of the Welding Process Using the Finite Element Method. ASME J. Pressure Vessel Technology, 1975, (97): 206-213
12 Shi Q. Y, Lu A. L, Zhao H. Y, etc al. Development and Application of Adaptive Mesh Technique in Three Dimensional Numerical Simulation of Welding Process. Acta Metall-urgica Sinica (English Letter ), 2000, 13(1): 33-39
13陈家权.焊接残余应力对疲劳裂纹萌生和扩展的影响.现代机械, 2000, (1): 47-49
14王国凡.钢结构焊接制造.北京:化学工业出版社, 2004: 21-33
15蔡志鹏,赵海燕,鹿安理等.焊接数值模拟中分段移动热源模型的建立及应用.中国机械工程, 2000, 21(3): 79-82
16 F. Jonassen, J. L. Meriam, E. P. Degarmo. Effect of Certain Block and Other Special Welding Procedures on Residual Welding Stresses. Weld Journal, 1946, 25(9): 492-496
17 E. F. Rybicki, P. A. Mcguire. The Effects of Induction Heating Conditions on Controlling Residual Stresses in Welded Pipes. J. Eng. Mater Technology Trans ASME, 1982, 104(4): 267-273
18 R. L. Koch, E. F. Rybicki, R. D. Strttan. A Computational Temperature Analysis for Induction Heating of Welded Pipes. J. Eng. Mater Technology, 1985, (107): 148-153
19 B. L. Josefson. Residual Stresses and Their Redistribution During Annealing of A Girth- butt Welded Thin-walled Pipe. Trans ASME J. Press Vessel Technology, 1982, (104): 245-250
20 B. L. Josefson. Stresses Redistribution During Annealing of a Multi-pass Welded pipe. J. Press Vessel Technology, 1983, (105): 165-170
21 F. W. Brust, E. F. Rybick. A Computational Model of Backlay Welding for Controlling Residual Stresses in Welded Pipe. J. Press Vessel Technology, 1981, (103): 226-32
22林燕,董俊慧,刘军.焊接残余应力数值模拟研究技术的现状与发展.焊接技术, 2003, 32(6): 5-7
23中国机械工程学会焊接学会.焊接手册(第2卷).北京:机械工业出版社, 2001
24江见鲸,何放法.有限元法及其应用.北京:机械工业出版社, 2006: 50-72
25张文钺.焊接传热学.北京:机械工业出版社, 1987: 1-57
26杨明.厚板焊接残余应力的有限元计算. [北京工业大学硕士论文]. 2003: 19-22
27黎江.三维焊接热应力和残余应力演化虚拟分析技术研究. [广西大学硕士论文]. 2002: 7-75
28周建新,李栋才,徐宏伟.焊接残余应力的研究与发展.金属成形工艺, 2003, 21(6): 62-64
29朱援祥,王勤.基于ANSYS平台的焊接残余应力模拟.武汉理工大学学报, 2004,126(2): 69-72
30 ANSYS, Inc. ANSYS Modeling and Meshing Guide. (Twelfth Edition). SAS IP, Inc. 2001: 1-21
31贾丽伟.钢结构中板件焊接残余应力数值模拟的研究. [燕山大学硕士论文]. 2005: 25-27
32龚曙光,谢桂兰. ANSYS操作命令与参数化编程.机械工业出版社, 2003: 1-238
33 ANSYS, Inc. ANSYS Elements Reference. Twelfth Edition. SAS IP, Inc. 2001: 11-19
34王助成,绍敏.有限单元法基本原理和数值方法.北京:清华大学出版社, 1997: 3-18
35赵明,武传松,陈茂爱.焊接热过程数值分析中相变潜热的三种解决方案.焊接学报, 2006, 27(9): 55-62
36 Y. I. Li, J. Wang, M. A. Chen, etc al. Finite Element Analysis of Residual Stress in the Welded Zone of a High Strength Steel. Indian Academy of Sciences, 2004, 27(2): 127-132
37周建兴,刘瑞祥,陈立亮等.凝固过程数值模拟中的潜热处理方法.铸造, 2001, 50(7): 404-407
38 Y. C. Lin, K. H. Lee. Effect of Preheating on the Residual Stress in Type 304Stainless Steel Weldment. Journal of Materials Proceeding Technology, 1997, (63): 797-801
39 Paveliv V, Tanbakuchi R, Auyehara O. Experimental and Computed Temperature Historips in Gas Tungsten Arc Welding of Thin Plates. Welding Journal Research Supplement, 1969, 48(7): 56-57
40赵学荣,朱援祥,孙秦明.对接焊缝残余应力的有限元分析.焊接计术, 2003, 32(5): 14-15
41朱援祥,王勤,赵学荣.基于Ansys平台的焊接残余应力模拟.武汉理工大学学报, 2004, 26(2): 69-72
42 X. K. Zhu, Y. J. Chao. Numerical Simulation of Transient Temperature and Residual Stresses in Friction Stir Welding of 304L Stainless Steel. Journal of Materials Processing Technology, 2004, (146): 263-272
43倪红芳,凌祥,涂善东.多道焊三维残余应力场有限元模拟.机械强度, 2004, 26(2): 218-222
44柴昶.厚板钢材在结构工程中的应用及其材性选用.钢结构, 2005, 119(74): 47-53
45朱援祥,王勤.基于ANSYS平台的焊接残余应力模拟.武汉理工大学学报, 2004,126(2): 69-72
46朱援祥,张小飞.基于有限元的多次补焊焊接残余应力的数值模.焊接学报, 2002, 123(1): 65-68
47李明,钟秉章.三峡工程压力钢管的焊接残余应与结构安全性分析.水力发电学报, 2001, 74(3): 96-107
48潘武生,王国顺.三峡水电站引水钢管焊接残余应力的有限元计算.水利电力机械, 2000, (3): 11-13
49 C. Carmignani, R. Mares, G. T. oselli. Transient Finite Element Analysis of Deep Penetration Laser Welding Process in a Singlepass Butt-welded Thick Steel Plate. Computer Methods in Applied Mechanics and Engineering, 1999, 179(3): 197-214
50 G. B. Jang, H. K. Kim, S. S. Kang. The Effects of Root Opening on Mechanical Properties, Deformation and Residual Stress of Weldments. Welding Journal, 2001, 80(3): 80-89
51 T. L. Teng, P. H. Chang, W. CH. Tseng. Effect of Welding Sequences on Residual Stresses. Computers and Structures, 2003, 81(5): 273-286
52 M. S. Watanabe, K. Satoh, K. Kimura. Effect of Welding Methods and Sequences on the Residual Stress Distribution of Welded Joints. Japan Weld Society, 1995, 24(4): 146-153
53 T. L. Teng, C.L.Chih. Effect of Welding Conditions on Residual Stresses Due to Butt Welds. International Journal of Pressure Vessels and Piping, 1998 (75):857-864
54 H. Ma, H. L. Deng. Nondestructive Determination of Welding Residual Stress by Boundary Element Method. Advanced in Engineering Software, 1998, 29(2), 89-95
55 Y. C. Lin and K. H. Lee. Effect of Preheating on the Residual Stress in Type 304Stainless Steel Weldment. Journal of Materials Proceeding Technology, 1997, (63): 797-801
56 X. K. Zhu, Y. J. Chao. Numerical Simulation of Transient Temperature and Residual Stresses in Friction Stir Welding of 304L Stainless Steel. Journal of Materials Processing Technology, 2004, (146): 263-272
57 S. Murugan, K. R. Sanjai, P. V. Kumar. Temperature Distribution and Residual Stress Due to Mutipass Welding in Type 304L Stainless Steel and Low Carbon Steel Weld Pads. International Journal of Pressure Vessels and Piping, 2000, (78): 307-317
58陈绍藩.钢结构设计原理.北京:科学出版社, 2003: 80-100
2 Lindgren L. E, Runnewalm H, Nasstron M. O. Simulation of Multi-pass Melding of a Thick plate. International Journal for Numerical Methods in Engineering, 1999, 44(9): 1301-1316
3 Zhao H. Y, Lu A. L, Shi Q. Y, etc al. Simulation of Welding Process of T-joints. Atca Metallurgical Sinica (English Letter), 2000, 13(1): 205-212
4 Xu Qinghong, Guo Wei , Tian Xiyang, etc al. Establishment and Verification of 3D temper ature Field Numerical Model. Transaction of the China Welding Institution, 1997, 8(2): 34-39
5 Karlsson R. I, Josefson B. L. Three-dimensional Finite Element Analysis of Temperature and Stresses in a Single-pass Butt-welded Pipe. ASME Journal of Pressure Vessel Techno logy, 1990, 112(2): 76-84
6 Eiji Takahash, Kenji Wai, Kunihiko Satoh. A Method of Measuring Triaxial Residual Stress in Heavy Section Butt Weldments. Trans of Japan Welding Society, 1997, 10(1): 36-45
7熊建民等.厚板焊接中残余应力的分布规律.湖北工学院学报, 1997, 9(2): 56-78
8王继峰.焊接温度场和应力场的热源模型研究. [燕山大学硕士论文]. 2006: 32-33
9 P. Dong, F. W. Brust. Welding Residual Stresses and Effects on Fracture in Pressure Vessel and Piping Components: A Millennium Review and Beyond. Journal of Pressure Vessel Technology, 2000, 122(3): 329-338
10 Kamichika, Ryoich, Yada, etc al. Internal Stresses in Thick Plates Weld-overlaid with Austenitic Stainless Steel EMDASH2. Transactions of the Japan Welding Society, 1974, 5(1): 22-31
11 Friedman. Thermomechanical Analysis of the Welding Process Using the Finite Element Method. ASME J. Pressure Vessel Technology, 1975, (97): 206-213
12 Shi Q. Y, Lu A. L, Zhao H. Y, etc al. Development and Application of Adaptive Mesh Technique in Three Dimensional Numerical Simulation of Welding Process. Acta Metall-urgica Sinica (English Letter ), 2000, 13(1): 33-39
13陈家权.焊接残余应力对疲劳裂纹萌生和扩展的影响.现代机械, 2000, (1): 47-49
14王国凡.钢结构焊接制造.北京:化学工业出版社, 2004: 21-33
15蔡志鹏,赵海燕,鹿安理等.焊接数值模拟中分段移动热源模型的建立及应用.中国机械工程, 2000, 21(3): 79-82
16 F. Jonassen, J. L. Meriam, E. P. Degarmo. Effect of Certain Block and Other Special Welding Procedures on Residual Welding Stresses. Weld Journal, 1946, 25(9): 492-496
17 E. F. Rybicki, P. A. Mcguire. The Effects of Induction Heating Conditions on Controlling Residual Stresses in Welded Pipes. J. Eng. Mater Technology Trans ASME, 1982, 104(4): 267-273
18 R. L. Koch, E. F. Rybicki, R. D. Strttan. A Computational Temperature Analysis for Induction Heating of Welded Pipes. J. Eng. Mater Technology, 1985, (107): 148-153
19 B. L. Josefson. Residual Stresses and Their Redistribution During Annealing of A Girth- butt Welded Thin-walled Pipe. Trans ASME J. Press Vessel Technology, 1982, (104): 245-250
20 B. L. Josefson. Stresses Redistribution During Annealing of a Multi-pass Welded pipe. J. Press Vessel Technology, 1983, (105): 165-170
21 F. W. Brust, E. F. Rybick. A Computational Model of Backlay Welding for Controlling Residual Stresses in Welded Pipe. J. Press Vessel Technology, 1981, (103): 226-32
22林燕,董俊慧,刘军.焊接残余应力数值模拟研究技术的现状与发展.焊接技术, 2003, 32(6): 5-7
23中国机械工程学会焊接学会.焊接手册(第2卷).北京:机械工业出版社, 2001
24江见鲸,何放法.有限元法及其应用.北京:机械工业出版社, 2006: 50-72
25张文钺.焊接传热学.北京:机械工业出版社, 1987: 1-57
26杨明.厚板焊接残余应力的有限元计算. [北京工业大学硕士论文]. 2003: 19-22
27黎江.三维焊接热应力和残余应力演化虚拟分析技术研究. [广西大学硕士论文]. 2002: 7-75
28周建新,李栋才,徐宏伟.焊接残余应力的研究与发展.金属成形工艺, 2003, 21(6): 62-64
29朱援祥,王勤.基于ANSYS平台的焊接残余应力模拟.武汉理工大学学报, 2004,126(2): 69-72
30 ANSYS, Inc. ANSYS Modeling and Meshing Guide. (Twelfth Edition). SAS IP, Inc. 2001: 1-21
31贾丽伟.钢结构中板件焊接残余应力数值模拟的研究. [燕山大学硕士论文]. 2005: 25-27
32龚曙光,谢桂兰. ANSYS操作命令与参数化编程.机械工业出版社, 2003: 1-238
33 ANSYS, Inc. ANSYS Elements Reference. Twelfth Edition. SAS IP, Inc. 2001: 11-19
34王助成,绍敏.有限单元法基本原理和数值方法.北京:清华大学出版社, 1997: 3-18
35赵明,武传松,陈茂爱.焊接热过程数值分析中相变潜热的三种解决方案.焊接学报, 2006, 27(9): 55-62
36 Y. I. Li, J. Wang, M. A. Chen, etc al. Finite Element Analysis of Residual Stress in the Welded Zone of a High Strength Steel. Indian Academy of Sciences, 2004, 27(2): 127-132
37周建兴,刘瑞祥,陈立亮等.凝固过程数值模拟中的潜热处理方法.铸造, 2001, 50(7): 404-407
38 Y. C. Lin, K. H. Lee. Effect of Preheating on the Residual Stress in Type 304Stainless Steel Weldment. Journal of Materials Proceeding Technology, 1997, (63): 797-801
39 Paveliv V, Tanbakuchi R, Auyehara O. Experimental and Computed Temperature Historips in Gas Tungsten Arc Welding of Thin Plates. Welding Journal Research Supplement, 1969, 48(7): 56-57
40赵学荣,朱援祥,孙秦明.对接焊缝残余应力的有限元分析.焊接计术, 2003, 32(5): 14-15
41朱援祥,王勤,赵学荣.基于Ansys平台的焊接残余应力模拟.武汉理工大学学报, 2004, 26(2): 69-72
42 X. K. Zhu, Y. J. Chao. Numerical Simulation of Transient Temperature and Residual Stresses in Friction Stir Welding of 304L Stainless Steel. Journal of Materials Processing Technology, 2004, (146): 263-272
43倪红芳,凌祥,涂善东.多道焊三维残余应力场有限元模拟.机械强度, 2004, 26(2): 218-222
44柴昶.厚板钢材在结构工程中的应用及其材性选用.钢结构, 2005, 119(74): 47-53
45朱援祥,王勤.基于ANSYS平台的焊接残余应力模拟.武汉理工大学学报, 2004,126(2): 69-72
46朱援祥,张小飞.基于有限元的多次补焊焊接残余应力的数值模.焊接学报, 2002, 123(1): 65-68
47李明,钟秉章.三峡工程压力钢管的焊接残余应与结构安全性分析.水力发电学报, 2001, 74(3): 96-107
48潘武生,王国顺.三峡水电站引水钢管焊接残余应力的有限元计算.水利电力机械, 2000, (3): 11-13
49 C. Carmignani, R. Mares, G. T. oselli. Transient Finite Element Analysis of Deep Penetration Laser Welding Process in a Singlepass Butt-welded Thick Steel Plate. Computer Methods in Applied Mechanics and Engineering, 1999, 179(3): 197-214
50 G. B. Jang, H. K. Kim, S. S. Kang. The Effects of Root Opening on Mechanical Properties, Deformation and Residual Stress of Weldments. Welding Journal, 2001, 80(3): 80-89
51 T. L. Teng, P. H. Chang, W. CH. Tseng. Effect of Welding Sequences on Residual Stresses. Computers and Structures, 2003, 81(5): 273-286
52 M. S. Watanabe, K. Satoh, K. Kimura. Effect of Welding Methods and Sequences on the Residual Stress Distribution of Welded Joints. Japan Weld Society, 1995, 24(4): 146-153
53 T. L. Teng, C.L.Chih. Effect of Welding Conditions on Residual Stresses Due to Butt Welds. International Journal of Pressure Vessels and Piping, 1998 (75):857-864
54 H. Ma, H. L. Deng. Nondestructive Determination of Welding Residual Stress by Boundary Element Method. Advanced in Engineering Software, 1998, 29(2), 89-95
55 Y. C. Lin and K. H. Lee. Effect of Preheating on the Residual Stress in Type 304Stainless Steel Weldment. Journal of Materials Proceeding Technology, 1997, (63): 797-801
56 X. K. Zhu, Y. J. Chao. Numerical Simulation of Transient Temperature and Residual Stresses in Friction Stir Welding of 304L Stainless Steel. Journal of Materials Processing Technology, 2004, (146): 263-272
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