小截面方管焊接变形研究
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摘要
火箭发动机核心部件束式喷管延伸段由大量的小截面方管焊接而成,焊接过程中产生的变形对发动机整体质量有重要影响。因此,研究小截面方管的变形规律及其控制方法,对于提高产品质量,具有重要的意义。
本文首先对小截面方管焊接过程的温度场进行分析和测量,采用接触传热的方法处理方管底部传热边界,并考虑了材料物理参数随温度的变化、对流和辐射传热及相变潜热,建立温度场-变形的直接耦合计算模型。与实测对比,计算结果与实测值较好的吻合,验证了模型的正确性。
针对多管多道焊接过程条件复杂,有限元模型网格数量巨大,计算速度慢,周期长的特点,通过对实际过程的分析,采用单元死活的方法,根据焊接顺序,逐步激活网格单元。同时,建立基于局域网的分布计算平台,采用3台计算机进行并行计算,提高计算速度,节省了大量的计算时间。
通过对小截面方管焊接过程进行数学分析和数值模拟,考察不同参数和焊接顺序对方管变形的影响规律。结果表明:在纵向热应力的作用下,方管将产生挠曲变形;横向力的作用将使方管产生弯曲和扭转;热源偏离焊缝中心将导致错边问题;热源前方的焊接间隙随热源移动动态变化。多管多道焊接时,采用对称排列焊接焊后横向变形比顺序排列焊接明显减小,焊接质量较好。通过上述结果,在实际中采用分段焊接及采用保持结构对称的焊接顺序,可以有效的减小焊接变形,提高焊接质量。
A large thin-walled weld structure is adopted in the manufacturing of rocket nozzle extension. The welding deformation has important effects on the rocket engine. Thus, it is meaningful to study the deformation laws and control methodology of thin-walled structure for improving the quality of products.
In this thesis, the temperature field of small-section square tubes was analyzed and measured firstly, disposing the pipe bottom heat border with contact convection method, considering the changes of material physical parameters with the temperature, convection and radiation heat transfer and latent fusion heat, the temperature-deformation direct coupling numerical model was built. It is shown that the simulation results are in good accordance with the actual results and proved the model is correct.
According to the complex conditions of multi-pipe multi-pass welding process, the finite element model has a huge mesh number, slow computing speed, and long cycle. By analyzing the actual process and adopting the active-deactivate element method, the mesh element was activated step by step according to the welding procedure. Meanwhile, the LAN-based distributed computing platform was constructed, using three computers for parallel computing, to improve the calculation speed and saving a lot of computing time.
By the mathematical analysis and numerical simulation of small-section tube welding process, the results show that the pipe has a deflection by the effect of vertical thermo stress; the pipe has a bend and a torsion by the effect of transverse stress; the excursion of heat source from the weld centre resulted in unfitness of butt joint ;the weld gap in front of heat source changed dynamically with the move of the heat source. In multi-pipe multi-pass welding, the transverse deformation after weld in symmetry welding was decreased compared with that in ordinal welding, and the weld quality is better. By the above results, adopting subsection welding method and the welding sequence with symmetry structure, the welding distortion can be decreased effectively, and the welding quality can be enhanced too.
本文首先对小截面方管焊接过程的温度场进行分析和测量,采用接触传热的方法处理方管底部传热边界,并考虑了材料物理参数随温度的变化、对流和辐射传热及相变潜热,建立温度场-变形的直接耦合计算模型。与实测对比,计算结果与实测值较好的吻合,验证了模型的正确性。
针对多管多道焊接过程条件复杂,有限元模型网格数量巨大,计算速度慢,周期长的特点,通过对实际过程的分析,采用单元死活的方法,根据焊接顺序,逐步激活网格单元。同时,建立基于局域网的分布计算平台,采用3台计算机进行并行计算,提高计算速度,节省了大量的计算时间。
通过对小截面方管焊接过程进行数学分析和数值模拟,考察不同参数和焊接顺序对方管变形的影响规律。结果表明:在纵向热应力的作用下,方管将产生挠曲变形;横向力的作用将使方管产生弯曲和扭转;热源偏离焊缝中心将导致错边问题;热源前方的焊接间隙随热源移动动态变化。多管多道焊接时,采用对称排列焊接焊后横向变形比顺序排列焊接明显减小,焊接质量较好。通过上述结果,在实际中采用分段焊接及采用保持结构对称的焊接顺序,可以有效的减小焊接变形,提高焊接质量。
A large thin-walled weld structure is adopted in the manufacturing of rocket nozzle extension. The welding deformation has important effects on the rocket engine. Thus, it is meaningful to study the deformation laws and control methodology of thin-walled structure for improving the quality of products.
In this thesis, the temperature field of small-section square tubes was analyzed and measured firstly, disposing the pipe bottom heat border with contact convection method, considering the changes of material physical parameters with the temperature, convection and radiation heat transfer and latent fusion heat, the temperature-deformation direct coupling numerical model was built. It is shown that the simulation results are in good accordance with the actual results and proved the model is correct.
According to the complex conditions of multi-pipe multi-pass welding process, the finite element model has a huge mesh number, slow computing speed, and long cycle. By analyzing the actual process and adopting the active-deactivate element method, the mesh element was activated step by step according to the welding procedure. Meanwhile, the LAN-based distributed computing platform was constructed, using three computers for parallel computing, to improve the calculation speed and saving a lot of computing time.
By the mathematical analysis and numerical simulation of small-section tube welding process, the results show that the pipe has a deflection by the effect of vertical thermo stress; the pipe has a bend and a torsion by the effect of transverse stress; the excursion of heat source from the weld centre resulted in unfitness of butt joint ;the weld gap in front of heat source changed dynamically with the move of the heat source. In multi-pipe multi-pass welding, the transverse deformation after weld in symmetry welding was decreased compared with that in ordinal welding, and the weld quality is better. By the above results, adopting subsection welding method and the welding sequence with symmetry structure, the welding distortion can be decreased effectively, and the welding quality can be enhanced too.
引文
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4汪建华,戚新海.三维瞬态焊接温度场的有限元模拟[J].上海交通大学学报. 1996, 30(3):120~125
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6李冬林,于有生,温家伶.堆焊温度场的三维动态有限元模拟[J].武汉理工大学学报, 2002,26(5):671~673
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13 D. Deng, H. Murakawa. Numerical Simulation of Temperature Field and Residual Stress in Multi-pass Welds in Stainless Steel Pipe and Comparison With Experimental Measurements. Computational Materials Science. 2005, 25(3):125~130
14 Fenggui Lu, Shun Yao, Songnian Lou. Modeling and Finite Element Analysis onGTAW Arc and Weld Pool. Computational Materials Sci-ence.2004, 29(3):371~378
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16余学进,张少钦,彭迎风等.三维H-自适应误差分析在焊接工程中的应用.暨南大学学报.2005,26(1):94~95
17武传松,王怀刚,张明贤.小孔等离子弧焊接热场瞬时演变过程的数值分析.金属学报.2006, 42(3):311~316
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19 Hibbitt, D Hugh, Marcal, V Pedro. Numerical, thermo-mechanical model for the welding and subsequent loading of a fabricated structure. Computers and Structures, 1973, 3(5):1145~1174
20 K Masubuchi. Prediction and control of residual stresses and distortion in welded structures. Proc. Theoretical Prediction in Joining and Welding (Osaka, Japan). 1996: 71~88
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22 L Karlsson. Thermal Stresses in Welding. R.Hetnarski (ed.).Thermal Stresses I. North-Holland. Amsterdam, 1986,5:299~389
23 N.Nasstrom. Combined 3-D and shell modeling of welding. Proc. IUTAM Symposium on the Mechanical Effects of Welding, Lulea, Sweden, Germany,1992:197~206
24 B.L. Josefson. Stress redistribution during local annealing of a multi-pass butt-welded pipe. J. Press vessel technology. 1986,108:125~130
25 J.B Leblond.A Theoretical and numerical approach to the plastic behavior of steels during phase transformations. J. Mech. Phys. Solids. 1986,34(4):395~409
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30汪建华等.焊接结构三维热变形的有限元模拟.上海交通大学学报.1994, 28(6):59~65
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33汪建华等.压缩机焊接变形的三维数值模拟.机械工程学报,1996,32(1):85~91
34汪建华等.薄板焊接失稳变形的热弹塑性有限元分析.计算机在焊接中应用的学术与技术交流会论文集.太原, 1996:190~193
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36蔡志鹏,鹿安理,赵海燕等.串热源模型及其在焊接数值模拟中的应用.中国机械工程, 2001, 37(4):25~28
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38蔡志鹏,鹿安理,史清宇等.焊接结构CAE中数值模拟技术的实现.中国机械工程. 2000, 11(7): 732~734
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2孟庆国,方洪渊,徐文立等.双丝焊热源模型.机械工程学报[J]. 2005, 41(4):110-113.
3陈翠欣,李午申,王庆鹏等.焊接温度场的三维动态有限元模拟.天津大学学报[J]. 2005, 38(5):466~470
4汪建华,戚新海.三维瞬态焊接温度场的有限元模拟[J].上海交通大学学报. 1996, 30(3):120~125
5朱援祥,张小飞,杨兵.基于有限元的多次补焊焊接残余应力的数值模拟[J].焊接学报. 2002, 23(1):65~68
6李冬林,于有生,温家伶.堆焊温度场的三维动态有限元模拟[J].武汉理工大学学报, 2002,26(5):671~673
7李亚江,沈孝芹,孟繁军.高强度钢焊接区拘束应力的有限元分析[J].焊接学报, 2002,23(5):57~64
8 C L Tsai,Z L Feng.A computational analysis of thermal and mechanical conditions for weld metal solidm cation cracking[J].Welding Research Abroad. 1996,42(1):34~141
9鹿安理,史清字,赵海燕.厚板焊接过程温度场、应力场的三维有限元数值模拟[J].中国机械工程,2001,12(2):183~185.
10 G Ravichandran, Raghupathy V P, N Ganesan. Analysis of emperature distribution during circumferential welding of cylindrical and spherical components using the finite element method[J]. Computers&Structures. 1996, 59(2):225~255.
11武传松.焊接热过程数值分析.哈尔滨工业大学出版社,1990
12陈楚等.数值分析在焊接中的应用.上海交通大学出版社,1985,1.80~82
13 D. Deng, H. Murakawa. Numerical Simulation of Temperature Field and Residual Stress in Multi-pass Welds in Stainless Steel Pipe and Comparison With Experimental Measurements. Computational Materials Science. 2005, 25(3):125~130
14 Fenggui Lu, Shun Yao, Songnian Lou. Modeling and Finite Element Analysis onGTAW Arc and Weld Pool. Computational Materials Sci-ence.2004, 29(3):371~378
15薛小龙,王志亮等. T形焊接接头的三维有限元模拟.中国机械工程. 2005, 16(9):811~815
16余学进,张少钦,彭迎风等.三维H-自适应误差分析在焊接工程中的应用.暨南大学学报.2005,26(1):94~95
17武传松,王怀刚,张明贤.小孔等离子弧焊接热场瞬时演变过程的数值分析.金属学报.2006, 42(3):311~316
18 ueda. Y. Analysis of the thermal elastic-plastic stress and strain during welding. Trans. Japan Welding Soc. 1971,2(2):90~100
19 Hibbitt, D Hugh, Marcal, V Pedro. Numerical, thermo-mechanical model for the welding and subsequent loading of a fabricated structure. Computers and Structures, 1973, 3(5):1145~1174
20 K Masubuchi. Prediction and control of residual stresses and distortion in welded structures. Proc. Theoretical Prediction in Joining and Welding (Osaka, Japan). 1996: 71~88
21 J Goldak. Thermal Stress Analysis of Welds. From melting point to room temperature. Proc. Theoretical Prediction in Joining and Welding (Osaka, Japan). 1996:225~230
22 L Karlsson. Thermal Stresses in Welding. R.Hetnarski (ed.).Thermal Stresses I. North-Holland. Amsterdam, 1986,5:299~389
23 N.Nasstrom. Combined 3-D and shell modeling of welding. Proc. IUTAM Symposium on the Mechanical Effects of Welding, Lulea, Sweden, Germany,1992:197~206
24 B.L. Josefson. Stress redistribution during local annealing of a multi-pass butt-welded pipe. J. Press vessel technology. 1986,108:125~130
25 J.B Leblond.A Theoretical and numerical approach to the plastic behavior of steels during phase transformations. J. Mech. Phys. Solids. 1986,34(4):395~409
26 Ueda Y, Nakacho.K. Theory of Thermal Elastic-plastic Analysis With a More General Work Harding Rule. Transaction of JWRI.1980, 19(1):107~114
27 Argyris.J, Simmat.J. Computational Aspects of Welding Stress Analysis. Computer Meth. Appl.Mech&Eng.1982, 133(4):625~666
28陈楚等.轴对称热弹塑性应力有限元分析在焊接中的应用.焊接学报.1987,8(4):196~203
29汪建华等.考虑相变的焊接动态和残余应力的研究.第六届全国焊接学术会议论文集.第5册,1990:209~212
30汪建华等.焊接结构三维热变形的有限元模拟.上海交通大学学报.1994, 28(6):59~65
31 J.Wang. etal.. Improvement in numerical accuracy and stability of 3-D FEM analysis in welding. Welding journal,1996,75(4):129s~134s
32汪建华等.管板接头三维焊接变形的数值模拟.焊接学报,1995,16(3):140~145
33汪建华等.压缩机焊接变形的三维数值模拟.机械工程学报,1996,32(1):85~91
34汪建华等.薄板焊接失稳变形的热弹塑性有限元分析.计算机在焊接中应用的学术与技术交流会论文集.太原, 1996:190~193
35汪建华等.预测焊接变形的残余塑变有限元方法.计算机在焊接中应用的学术与技术交流会论文集.太原, 1996:194~197
36蔡志鹏,鹿安理,赵海燕等.串热源模型及其在焊接数值模拟中的应用.中国机械工程, 2001, 37(4):25~28
37蔡志鹏,史清宇,赵海燕等.焊接过程仿真领域的若干关键技术问题及其初步研究.中国机械工程. 2000, 11(12): 201 ~205
38蔡志鹏,鹿安理,史清宇等.焊接结构CAE中数值模拟技术的实现.中国机械工程. 2000, 11(7): 732~734
39蔡志鹏,鹿安理,史清宇等.相似理论在焊接温度场和应力场及应变场中的应用.焊接学报. 2000, 21 ( 3 ): 79~82
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