冲击载荷作用下压力容器用金属材料动态断裂行为的研究
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摘要
压力容器和输油输气管道的爆裂、止裂,核电站防护的冲击安全,建筑物和结构的抗震设计等领域都涉及结构材料动态断裂的性能评估和灾害对策研究。为保证这些可能承受动载荷金属构件的安全可靠,需要在设计中预防含裂纹构件在冲击载荷下的起裂和扩展,因此研究金属材料动态断裂行为的重要意义是不言而喻的。本文从理论、试验和数值模拟方面研究了冲击载荷作用下金属材料的动态断裂行为,主要研究内容包括以下几个方面：
研究了中心裂纹板试样、双悬臂梁试样和三点弯曲试样在理想冲击载荷作用下,各种因素对于它们动态应力强度因子K1(t)的影响。分析中心裂纹板的计算结果表明动态应力强度因子的最大值一般发生在应力波与裂尖相互作用的时刻。双悬臂梁DCB试样模型在拉伸阶跃载荷的作用下,应力强度因子的动载系数可以近似用一个周期函数表示,它的变化周期与载荷加载点的位移变化周期相同。使用弹簧质量模型对三点弯曲试样的动态应力强度因子进行了求解,并使用此模型计算了试样在三种理想冲击载荷下的动态应力强度因子变化曲线；同时进行了完全的动态有限元分析,将计算结果与弹簧质量模型的结果进行了比较。
在-196℃下对S30408奥氏体不锈钢的母材和焊缝进行了夏比摆锤冲击试验研究。使用改进型柔度变化率法得到了低温下不锈钢母材夏比冲击试样的起裂点,通过对比发现改进型法得到的结果比传统的柔度变化率法得到的结果更加准确。根据试验得到的载荷位移曲线,结合Schindler方法和关键曲线法各自所得结果的优点,研究得到了不锈钢母材的动态J积分裂纹扩展阻力曲线(动态J-R曲线)。依据不锈钢焊缝在低温动载下的载荷位移曲线及其断裂特征,采用线弹性断裂力学模型计算了其动态断裂韧性,并对结果的有效性进行了讨论。
对典型压力容器用钢Q345R预制裂纹夏比冲击试样进行示波冲击试验,得到其载荷位移曲线。分别采用J积分增量方程计算方法和Schindler方法计算得到了Q345R材料在冲击加载速率下的动态裂纹扩展阻力曲线,并将两者结果进行了对比验证。将所得到的动态J-R曲线与准静态加载条件下得到的J-R曲线结果进行分析,发现动态加载条件下的J-R曲线要高于准静态加载下相应的结果。根据得到的试验数据建立了Q345R准静态和动态裂纹扩展阻力曲线之间关系的计算方程。
在-40℃下对Q345R材料进行了示波冲击试验,发现有预制疲劳裂纹的夏比冲击试样断口完全表现为解理断裂；而标准夏比冲击试样则在缺口处有少量的塑性变形,随后也发生解理断裂,得到的冲击功值更低。使用标准ASME E399中的准静态计算公式计算了两种试样的动态断裂韧性,并对结果进行了讨论。将断裂时间与试样振动周期比较验证了试验结果的有效性。应用大型通用有限元软件ABAQUS对Q345R材料在-40℃下的示波冲击试验进行了数值模拟,并采用基于节点位移外推法计算了在试样起裂时刻的动态应力强度因子,发现剔除裂尖附近的位移数据反而能增加计算结果的精度。
使用ABAQUS有限元软件并结合3D断裂力学软件ZENCRACK建立了三维有限元模型,对霍普金森压杆测试材料动态断裂韧性进行了数值模拟研究,同时建立了二维平面应变有限元模型,并进行了计算。有限元模型包括整个实验装置——子弹、入射杆、试样和支座,对三种不同初始裂纹长度的三点弯曲试样在同一速度子弹打击下进行了计算。起裂时问通过RKR局部应力断裂准则获得,结合计算得到的动态应力强度因子冲击响应曲线,最终得到材料动态断裂韧性,并验证了其有效性。以试验结果为基准,将三维和二维有限元计算结果的对比,发现三维有限元的计算结果要优于二维模型的计算结果。
Performance assessments and disaster countermeasures of dynamic fracture of structural materials are involved in many engineering fields such as pressure vessels and pipelines burst, crack arrest, the impact of the nuclear power plant protection security, buildings and structures, seismic design etc.. In order to ensure the safety and reliability of the metal components under dynamic loads, crack initiation and propagation in the componemts with prefabricated crack should be prevend in impact loading design. Therefore, the importance of study on dynamic fracture behavior of metallic materials is self-evident. The present dissertation investigates the dynamic fracture behavior of metallic materials under impact loads via theoretical analyses, experimental test and numerical simulation. The main contents in the dissertation are listed as following.
The effects of variety factors on the dynamic stress intensity factor under ideal impact loads are studied for plate with centeral prefabricated crack, twin cantilever beam and three point bend specimens. The calculated results of the plate with centeral prefabricated crack show that the maximum value of dynamic stress intensity factor generally occurs at the moment of intersection of the stress wave with crack tip. The stress intensity factor of twin cantilever beam can be approximated by a periodic function under tensile step load. The change cycle is as the same as the displacement cycle of loading point, and is a function of prefabricated crack. Spring-mass model is used to solve the dynamic stress intensity factor of the three-point bend specimens, and also be used to calculate the values of dynamic stress intensity factors under three ideal impact loads. The calculation results of completely dynamic finite element analysis are compared with the spring-mass model results.
Charpy pendulum impact tests are carried out on S30408austenitic stainless steel base metal and weld metal under-196℃. Modified compliance changing rate method is used to obtain the crack initiation point of stainless steel base metal charpy specimen. The analysis show that results obtained by the improved method is more accurate than that by traditional compliance changing rate method. Schindler procedure and key curve method are used in conjuction to get approaching real dynamic crack growth resistance curve in terms of load-displacement curves by tests. According to characteristics of fracture mechanism and load-displacement curves, linear elastic fracture mechanics approach is used to obtain the dynamic fracture toughness of weld metal.
Oscillographic impact tests are carried out using precracked charpy speciments of typical pressure vessel steel Q345R, the load-displacement curves are obtained. J-integral incremental equation procedure and Schindler method are used to estimate dynamic crack resistance curve of Q345R under impact loading rate respectively. The obtained results are consistent each other. By comparing the dynamic J-R curve and qusi-static J-R curve, it is found that the J-R curve under dynamic loading conditions is higher than that obtained under quasi-static loadings. A large number of experimental results show that there is a certain quantitative relationship between them. A calculation equation is established between Q345R quasi-static and dynamic crack growth resistance curve according to the obtained test data.
Oscillographic impact test of material Q345R are carried out under temperature-40℃. It is found that prefabricated fatigue crack charpy specimens show completely cleavage fracture performance. Standard charpy impact test specimen have small amount of plastic deformation in the gap. Fracture surfaces of specimens without inclusions are flatter and have lower impact energy value. The quasi static formula in standard ASME E399are used to calculate dynamic fracture toughness for samples of two types, the results are compared and discussed. The rupture time is compared with specimen vibration cycle to verify the validity of the test results. Numerical simulation of these tests is performed with the well known general purpose finite element software ABAQUS. Dynamic stress intensity factor at crack initiation is calculated based on the nodal displacements extrapolation. It is found that the calculation accuracy can be increased if excluding displacement data in the vicinity of crack tip.
3D and2D numerical simulations are also conducted for Dynamic fracture toughness test using TPB specimen in SHPB by the ABAQUS6.8code and3D fracture mechanics ZENCRACK7.7code.The finite element model includes the whole experimental system (the projectile, the input bar, the specimen and the supporting device). Three specimens with different initial crack length impacted by projectiles are calculated. Dynamic stress intensity factor impulse response curves are obtained. The dynamic initial fracture time, tf, can be received by RKR local stress fracture criterion. The material dynamic fracture toughness is successfully obtained from numerical simulation. The3D finite element results and2D results are compared with test results benchmark, it is found that3D finite element results are better than2D results.
研究了中心裂纹板试样、双悬臂梁试样和三点弯曲试样在理想冲击载荷作用下,各种因素对于它们动态应力强度因子K1(t)的影响。分析中心裂纹板的计算结果表明动态应力强度因子的最大值一般发生在应力波与裂尖相互作用的时刻。双悬臂梁DCB试样模型在拉伸阶跃载荷的作用下,应力强度因子的动载系数可以近似用一个周期函数表示,它的变化周期与载荷加载点的位移变化周期相同。使用弹簧质量模型对三点弯曲试样的动态应力强度因子进行了求解,并使用此模型计算了试样在三种理想冲击载荷下的动态应力强度因子变化曲线；同时进行了完全的动态有限元分析,将计算结果与弹簧质量模型的结果进行了比较。
在-196℃下对S30408奥氏体不锈钢的母材和焊缝进行了夏比摆锤冲击试验研究。使用改进型柔度变化率法得到了低温下不锈钢母材夏比冲击试样的起裂点,通过对比发现改进型法得到的结果比传统的柔度变化率法得到的结果更加准确。根据试验得到的载荷位移曲线,结合Schindler方法和关键曲线法各自所得结果的优点,研究得到了不锈钢母材的动态J积分裂纹扩展阻力曲线(动态J-R曲线)。依据不锈钢焊缝在低温动载下的载荷位移曲线及其断裂特征,采用线弹性断裂力学模型计算了其动态断裂韧性,并对结果的有效性进行了讨论。
对典型压力容器用钢Q345R预制裂纹夏比冲击试样进行示波冲击试验,得到其载荷位移曲线。分别采用J积分增量方程计算方法和Schindler方法计算得到了Q345R材料在冲击加载速率下的动态裂纹扩展阻力曲线,并将两者结果进行了对比验证。将所得到的动态J-R曲线与准静态加载条件下得到的J-R曲线结果进行分析,发现动态加载条件下的J-R曲线要高于准静态加载下相应的结果。根据得到的试验数据建立了Q345R准静态和动态裂纹扩展阻力曲线之间关系的计算方程。
在-40℃下对Q345R材料进行了示波冲击试验,发现有预制疲劳裂纹的夏比冲击试样断口完全表现为解理断裂；而标准夏比冲击试样则在缺口处有少量的塑性变形,随后也发生解理断裂,得到的冲击功值更低。使用标准ASME E399中的准静态计算公式计算了两种试样的动态断裂韧性,并对结果进行了讨论。将断裂时间与试样振动周期比较验证了试验结果的有效性。应用大型通用有限元软件ABAQUS对Q345R材料在-40℃下的示波冲击试验进行了数值模拟,并采用基于节点位移外推法计算了在试样起裂时刻的动态应力强度因子,发现剔除裂尖附近的位移数据反而能增加计算结果的精度。
使用ABAQUS有限元软件并结合3D断裂力学软件ZENCRACK建立了三维有限元模型,对霍普金森压杆测试材料动态断裂韧性进行了数值模拟研究,同时建立了二维平面应变有限元模型,并进行了计算。有限元模型包括整个实验装置——子弹、入射杆、试样和支座,对三种不同初始裂纹长度的三点弯曲试样在同一速度子弹打击下进行了计算。起裂时问通过RKR局部应力断裂准则获得,结合计算得到的动态应力强度因子冲击响应曲线,最终得到材料动态断裂韧性,并验证了其有效性。以试验结果为基准,将三维和二维有限元计算结果的对比,发现三维有限元的计算结果要优于二维模型的计算结果。
Performance assessments and disaster countermeasures of dynamic fracture of structural materials are involved in many engineering fields such as pressure vessels and pipelines burst, crack arrest, the impact of the nuclear power plant protection security, buildings and structures, seismic design etc.. In order to ensure the safety and reliability of the metal components under dynamic loads, crack initiation and propagation in the componemts with prefabricated crack should be prevend in impact loading design. Therefore, the importance of study on dynamic fracture behavior of metallic materials is self-evident. The present dissertation investigates the dynamic fracture behavior of metallic materials under impact loads via theoretical analyses, experimental test and numerical simulation. The main contents in the dissertation are listed as following.
The effects of variety factors on the dynamic stress intensity factor under ideal impact loads are studied for plate with centeral prefabricated crack, twin cantilever beam and three point bend specimens. The calculated results of the plate with centeral prefabricated crack show that the maximum value of dynamic stress intensity factor generally occurs at the moment of intersection of the stress wave with crack tip. The stress intensity factor of twin cantilever beam can be approximated by a periodic function under tensile step load. The change cycle is as the same as the displacement cycle of loading point, and is a function of prefabricated crack. Spring-mass model is used to solve the dynamic stress intensity factor of the three-point bend specimens, and also be used to calculate the values of dynamic stress intensity factors under three ideal impact loads. The calculation results of completely dynamic finite element analysis are compared with the spring-mass model results.
Charpy pendulum impact tests are carried out on S30408austenitic stainless steel base metal and weld metal under-196℃. Modified compliance changing rate method is used to obtain the crack initiation point of stainless steel base metal charpy specimen. The analysis show that results obtained by the improved method is more accurate than that by traditional compliance changing rate method. Schindler procedure and key curve method are used in conjuction to get approaching real dynamic crack growth resistance curve in terms of load-displacement curves by tests. According to characteristics of fracture mechanism and load-displacement curves, linear elastic fracture mechanics approach is used to obtain the dynamic fracture toughness of weld metal.
Oscillographic impact tests are carried out using precracked charpy speciments of typical pressure vessel steel Q345R, the load-displacement curves are obtained. J-integral incremental equation procedure and Schindler method are used to estimate dynamic crack resistance curve of Q345R under impact loading rate respectively. The obtained results are consistent each other. By comparing the dynamic J-R curve and qusi-static J-R curve, it is found that the J-R curve under dynamic loading conditions is higher than that obtained under quasi-static loadings. A large number of experimental results show that there is a certain quantitative relationship between them. A calculation equation is established between Q345R quasi-static and dynamic crack growth resistance curve according to the obtained test data.
Oscillographic impact test of material Q345R are carried out under temperature-40℃. It is found that prefabricated fatigue crack charpy specimens show completely cleavage fracture performance. Standard charpy impact test specimen have small amount of plastic deformation in the gap. Fracture surfaces of specimens without inclusions are flatter and have lower impact energy value. The quasi static formula in standard ASME E399are used to calculate dynamic fracture toughness for samples of two types, the results are compared and discussed. The rupture time is compared with specimen vibration cycle to verify the validity of the test results. Numerical simulation of these tests is performed with the well known general purpose finite element software ABAQUS. Dynamic stress intensity factor at crack initiation is calculated based on the nodal displacements extrapolation. It is found that the calculation accuracy can be increased if excluding displacement data in the vicinity of crack tip.
3D and2D numerical simulations are also conducted for Dynamic fracture toughness test using TPB specimen in SHPB by the ABAQUS6.8code and3D fracture mechanics ZENCRACK7.7code.The finite element model includes the whole experimental system (the projectile, the input bar, the specimen and the supporting device). Three specimens with different initial crack length impacted by projectiles are calculated. Dynamic stress intensity factor impulse response curves are obtained. The dynamic initial fracture time, tf, can be received by RKR local stress fracture criterion. The material dynamic fracture toughness is successfully obtained from numerical simulation. The3D finite element results and2D results are compared with test results benchmark, it is found that3D finite element results are better than2D results.
引文
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