导弹油箱焊接有限元前处理实现及焊接顺序优化
|
摘要
随着计算机技术的发展,有限元数值模拟已经被广泛地应用到焊接领域的理论研究和实际应用中,越来越多的企业开始关注数值模拟工作,并希望利用数值模拟技术解决实际生产问题。但是,目前的有限元计算软件一般都是从欧美等西方发达国家引进,为通用软件,并不是针对特定领域设计,且操作极其复杂,加上全英文界面,从而限制了数值模拟技术在企业中的广泛应用。本文针对这一现状开发了一个专门针对焊接过程数值模拟的有限元前处理系统,并应用该系统建立了某型号导弹油箱结构的焊接有限元模型,分析了该结构的焊后变形规律。
该前处理系统界面简洁明了,操作简单方便,用户按照该系统界面进行操作即可完成模型网格划分、材料性能参数的输入、热源模型选择及焊接参数的输入、以及初始条件和边界条件的设置添加,为模拟计算做好准备,从而使工厂的一般技术人员也能完成焊接过程的模拟计算。
对于某型号导弹油箱结构焊接过程的数值模拟计算,主要考察了每块立板上各段焊缝焊接顺序的调整、四块立板之间不同的焊接顺序以及焊接起始端的选择对结构焊后变形的影响规律,模拟结果表明:壁板在各种焊接顺序下的整体变形规律基本相似,即焊后壁板沿焊缝纵向发生了向下的挠曲变形,中部向下变形量最大;沿焊缝横向发生了向上的挠曲变形,壁板两端部变形量较大,且壁板前端变形大于壁板后端。各种焊接顺序下的壁板变形相差不大,但对于单块立板而言,先点固两端然后交错对称焊接;在整体结构焊接过程中,对四块立板依次焊接相同位置的焊缝,此时壁板焊后变形最小。焊接起始端的选择对壁板焊后变形影响不大。盖板结构焊后基本未产生焊接变形。采用设计的焊接顺序在导弹油箱壁板实际结构上进行焊接并对焊后壁板变形进行了测量,测量所得的壁板变形规律与模拟计算结果吻合良好。
As a result of high speed evolution in computer science, the applications of Finite Element Method (FEM) were developed in theoretical and practical researches of welding, which got more and more attentions from numerous enterprises. The final goal of these researches was using FEM to solve the problems in the manufacture and production. However, some things limited the development of FEM technology in China. For example, most of the simulation software was from the developed countries like Europe and America, and this software was not easy to operate with a complex interface in English and not specialization in the particular research field or special purpose. To solve these problems, a FEM preprocessing system in materials joining process has been developed in this dissertation. Based on this system, a welding numerical model of a missile’s oil box has been established and the structure’s distortion rules after welding have been analyzed.
The control panel of this preprocessing system is simple and convenient. The friendly interface between computer and human allows the users easy to complete all the preprocessing operations, including the model’s meshing, the setup of the material parameter and welding processing parameter, the initial conditions and boundary conditions’definition etc, preparing for the simulation subsequently. So any operator with lack of knowledge in FEM or English can finish the welding simulation during using this preprocessing system.
As an application of this FEM preprocessing system, the simulation on the welding process of missile’s oil box was performed, in which the effects of the welding sequences of four web plates and welds on each web plate are primarily analyzed. The simulation results show that the deformations under varied welding sequences are almost the same. Downward deflection deformation is obtained along the weld longitudinal direction in the structure as well as upward deflection deformation along the weld traverse direction. The welding start location has little effect on the deformation of the structure. The minimal deformation of the structure is obtained using the method presented as follows: four web plates are first tack welded on both ends, and then the web plates are
该前处理系统界面简洁明了,操作简单方便,用户按照该系统界面进行操作即可完成模型网格划分、材料性能参数的输入、热源模型选择及焊接参数的输入、以及初始条件和边界条件的设置添加,为模拟计算做好准备,从而使工厂的一般技术人员也能完成焊接过程的模拟计算。
对于某型号导弹油箱结构焊接过程的数值模拟计算,主要考察了每块立板上各段焊缝焊接顺序的调整、四块立板之间不同的焊接顺序以及焊接起始端的选择对结构焊后变形的影响规律,模拟结果表明:壁板在各种焊接顺序下的整体变形规律基本相似,即焊后壁板沿焊缝纵向发生了向下的挠曲变形,中部向下变形量最大;沿焊缝横向发生了向上的挠曲变形,壁板两端部变形量较大,且壁板前端变形大于壁板后端。各种焊接顺序下的壁板变形相差不大,但对于单块立板而言,先点固两端然后交错对称焊接;在整体结构焊接过程中,对四块立板依次焊接相同位置的焊缝,此时壁板焊后变形最小。焊接起始端的选择对壁板焊后变形影响不大。盖板结构焊后基本未产生焊接变形。采用设计的焊接顺序在导弹油箱壁板实际结构上进行焊接并对焊后壁板变形进行了测量,测量所得的壁板变形规律与模拟计算结果吻合良好。
As a result of high speed evolution in computer science, the applications of Finite Element Method (FEM) were developed in theoretical and practical researches of welding, which got more and more attentions from numerous enterprises. The final goal of these researches was using FEM to solve the problems in the manufacture and production. However, some things limited the development of FEM technology in China. For example, most of the simulation software was from the developed countries like Europe and America, and this software was not easy to operate with a complex interface in English and not specialization in the particular research field or special purpose. To solve these problems, a FEM preprocessing system in materials joining process has been developed in this dissertation. Based on this system, a welding numerical model of a missile’s oil box has been established and the structure’s distortion rules after welding have been analyzed.
The control panel of this preprocessing system is simple and convenient. The friendly interface between computer and human allows the users easy to complete all the preprocessing operations, including the model’s meshing, the setup of the material parameter and welding processing parameter, the initial conditions and boundary conditions’definition etc, preparing for the simulation subsequently. So any operator with lack of knowledge in FEM or English can finish the welding simulation during using this preprocessing system.
As an application of this FEM preprocessing system, the simulation on the welding process of missile’s oil box was performed, in which the effects of the welding sequences of four web plates and welds on each web plate are primarily analyzed. The simulation results show that the deformations under varied welding sequences are almost the same. Downward deflection deformation is obtained along the weld longitudinal direction in the structure as well as upward deflection deformation along the weld traverse direction. The welding start location has little effect on the deformation of the structure. The minimal deformation of the structure is obtained using the method presented as follows: four web plates are first tack welded on both ends, and then the web plates are
引文
1J.H.Wang, H.Lu and Murakawa. Mechanical Behavior in Local Post HeatTreatment(Report 1) Visco-elastic-plastic FEM Analysis of Local PWHT.Trans of JWRI. 1998,27(1):83~88
2刘仁培, 董祖珏, 魏艳红. 焊接凝固裂纹数值模拟前处理系统. 第十次全国焊接学会论文集(1). 哈尔滨. 黑龙江人民出版社,2001:201~204
3张玉林. 不锈钢焊接凝固裂纹的数值模拟与预测系统. 哈尔滨工业大学工学硕士学位论文. 2005:1~50
4郑荣, 庞茂. AutoCAD ActiveX 技术在有限元前处理中的应用. 水利电力机械. 2003,25(4):48~52
5吴士平, 宁志良. 铸件凝固数值模拟前处理的研究. 哈尔滨电工学院学报.1996,19(2):226~231
6谢刚, 王小林. MATLAB 与 ANSYS 数据接口的开发研究及应用. 机械工程与自动化. 2005, (2):52~55
7沈军. AutoCAD 在有限元前处理中的应用. 经验与技巧. 2001, (10):40~41
8孙旭峰. 基于数据库和图形系统的有限元前处理的实现. 计算机辅助工程. 2002, (3):37~42
9杨慧. 基于 ObjectARX 的有限元系统集成及其在车轮成形中的应用. 锻压技术. 2003, (6):1~5
10 潘晋, 邓安福, 干腾君. AutoCAD VBA 开发技术在有限元前处理程序中的应用. 地下空间. 2003,23(1):52~57
11 王开云, 何江达, 李莉. AutoCAD 及 Visual Lisp 语言在有限元前处理中的应用. 产品与应用. 2004, (1):88~91
12 梁声闻, 杨新华. ANSYS 前处理与 AutoCAD 的系统集成. 华中科技大学学报. 2004,21(1):81~85
13 蔡洪能, 王雅生, 张国栋. 三维复杂焊接结构有限元分析前处理. 焊管.2001, 24(2):19~21
14 吴言高. 焊接数值模拟技术发展现状.焊接学报. 2002, (6):89~92
15 汪建华 , 陆皓 . 焊接预测理论和数值模拟技术的发展 . 造船技术 .2001,4(3):21~24
16 Y. M. Zhang, R. Kovacevic. Dynamic Analysis and Identification of GasTungsten are Welding Process for Weld Penetration Control. Journal ofEngineering for Industry Transactions of the ASME. 1996,118(1):123~135
17 J.W. Kim, S.J. Na. A Study on the 3-dimensional Analysis of Heat and Fluid-flow in Gas Metal Arc-welding Using Boundary-fitted Coordinates. Journalof Engineering for Industry Transactions of the ASME. 1994,116(1):78~85
18 刘仁培, 董祖珏, 魏艳红. 不锈钢焊接凝固裂纹应力应变场数值模拟模型的建立. 焊接学报. 1999,20(4):38~43
19 魏艳红, 刘仁培. 不锈钢焊接凝固裂纹应力应变场数值模拟结果分析. 焊接学报. 2000,21(2):36~38
20 L.M.Habib, U.Kleen. Numerical Simulation of Weld Residual Stresses andCountermeasures in Austenitic Steel Piping. International Conference onNuclear Engineering. 1997:25~29
21 汪建华, 戚新海, 钟小敏. 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
22 J.A. Goldak. Error Due to Two Dimensional Approximation in Heat TransferAnalysis of Welding. Welding Journal.1993,72(9):440~446
23 S. Brown, H. Song. Finite Element Simulation of Welding of LargeStructures. Journal of Engineering for Industry Transactions of ASME.1992,114(4):441~451
24 P.S. Wei, W.H. Giedt. Surface Tension Gradient – Driven Flow around anElectron Beam Welding Cavity. Welding Journal. 1985,64(9):251~259
25 Z.C. Lin, W.C. Pan. A Coupled Thermo-elastic-plastic Model with aModified Direct Interaction Method In a Cold Extrusion Process. Journal ofStrain Analysis. 1993,128(2): 89~100
26 Y. Ueda. Analysis of the Thermal Elastic-plastic Stress and Strain duringWelding. Trans. Japan Welding Soc.. 1971,2(2):90~100
27 H.D. Hibbitt, P.V. Marcal. A Numerical Thermo-mechanical Model for theWelding and Subsequent Loading of a Fabricated Structure. Computer&Structure. 1973,3(5):1145~1174
28 K. Masubuchi. Prediction and Control of Residual Stresses and Distortion inWelded Structures. Proc. Theoretical Prediction in Joining and Welding.1996:71~88
29 Goldak J. Thermal Stress Analysis of Welds. From Melting Point to RoomTemperature. Proc. Theoretical Prediction in Joining and Welding.1996:225~230
30 L. Karlsson. Thermo-mechanical FE-analysis of Residual Stresses and StressRedistribution in Butt Welding of a Copper Canister for Spent Nuclear Fuel.Nuclear Engineering and Design. 2002,212(1):401~408
31 N.Nasstrom. Combined 3-D and Shell Modeling of Welding. Proc. IUTAMSymposium on the Mechanical Effects of Welding. Lulea, Sweden, Germany,1992:197~206
32 J.B.Leblond. A Theoretical and Numerical Approach to the Plastic BehaviorofSteelsduringPhaseTransformations.J.Mech.Phys.Solids.1986,34(4):395~409
33 Y.Ueda, K.Nakacho. Theory of Thermal Elastic-plastic Analysis with a MoreGeneral Work Harding Rule. Transaction of JWRI. 1980, 19(1):107~114
34 J.Argyris, J.Simmat. Computational Aspects of Welding Stress Analysis.Computer Meth. Appl.Mech&Eng. 1982, 133(4):625~666
35 B. Anderson. Thermal Stress in Large Butt-welded Plates. Journal of ThermalStress. 1981, (4):492~500
36 Ф.Grong. Metallurgical Modeling of Welding. The Institute of Materials.1994:56~60
37 Tso-Liang Teng, Chin-Ping Fung, Peng-Hsiang Chang, Wei-Chun Yang.Ananlysis of Residual Stresses and Distortions in T-joint Fillet Welds.International Journal of Pressure Vessels and Piping. 2001,78:523~538
38 薛小龙, 桑芝富, 朱加贵. 多道间断焊 T 型接头的数值模拟. 设计计算.2004,11(21):27~31
39 唐慕尧. 单面焊时终端裂纹的研究. 焊接学报. 1987,7(3):123~132
40 陈楚. 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
41 汪建华. 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. 西安, 1990:209~212
42 汪建华 . 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
43 J. Wang. Improvement in Numerical Accuracy and Stability of 3-D FEMAnalysis in Welding. Welding Journal. 1996,75(4):129~134
44 汪建华. 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
45 汪建华. 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
46 赵海燕, 鹿安理, 史清宇. 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
47 鹿安理, 史静, 赵海燕. 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(2):201~205
48 史清宇. 焊接过程三维数值模拟的研究及应用. 清华大学博士学位论文.2000:40~90
49 田锡唐. 焊接结构. 机械工业出版社, 1981:17~46
50 刘庄. 热处理过程的数值模拟. 科学出版社, 1996:58~59
2刘仁培, 董祖珏, 魏艳红. 焊接凝固裂纹数值模拟前处理系统. 第十次全国焊接学会论文集(1). 哈尔滨. 黑龙江人民出版社,2001:201~204
3张玉林. 不锈钢焊接凝固裂纹的数值模拟与预测系统. 哈尔滨工业大学工学硕士学位论文. 2005:1~50
4郑荣, 庞茂. AutoCAD ActiveX 技术在有限元前处理中的应用. 水利电力机械. 2003,25(4):48~52
5吴士平, 宁志良. 铸件凝固数值模拟前处理的研究. 哈尔滨电工学院学报.1996,19(2):226~231
6谢刚, 王小林. MATLAB 与 ANSYS 数据接口的开发研究及应用. 机械工程与自动化. 2005, (2):52~55
7沈军. AutoCAD 在有限元前处理中的应用. 经验与技巧. 2001, (10):40~41
8孙旭峰. 基于数据库和图形系统的有限元前处理的实现. 计算机辅助工程. 2002, (3):37~42
9杨慧. 基于 ObjectARX 的有限元系统集成及其在车轮成形中的应用. 锻压技术. 2003, (6):1~5
10 潘晋, 邓安福, 干腾君. AutoCAD VBA 开发技术在有限元前处理程序中的应用. 地下空间. 2003,23(1):52~57
11 王开云, 何江达, 李莉. AutoCAD 及 Visual Lisp 语言在有限元前处理中的应用. 产品与应用. 2004, (1):88~91
12 梁声闻, 杨新华. ANSYS 前处理与 AutoCAD 的系统集成. 华中科技大学学报. 2004,21(1):81~85
13 蔡洪能, 王雅生, 张国栋. 三维复杂焊接结构有限元分析前处理. 焊管.2001, 24(2):19~21
14 吴言高. 焊接数值模拟技术发展现状.焊接学报. 2002, (6):89~92
15 汪建华 , 陆皓 . 焊接预测理论和数值模拟技术的发展 . 造船技术 .2001,4(3):21~24
16 Y. M. Zhang, R. Kovacevic. Dynamic Analysis and Identification of GasTungsten are Welding Process for Weld Penetration Control. Journal ofEngineering for Industry Transactions of the ASME. 1996,118(1):123~135
17 J.W. Kim, S.J. Na. A Study on the 3-dimensional Analysis of Heat and Fluid-flow in Gas Metal Arc-welding Using Boundary-fitted Coordinates. Journalof Engineering for Industry Transactions of the ASME. 1994,116(1):78~85
18 刘仁培, 董祖珏, 魏艳红. 不锈钢焊接凝固裂纹应力应变场数值模拟模型的建立. 焊接学报. 1999,20(4):38~43
19 魏艳红, 刘仁培. 不锈钢焊接凝固裂纹应力应变场数值模拟结果分析. 焊接学报. 2000,21(2):36~38
20 L.M.Habib, U.Kleen. Numerical Simulation of Weld Residual Stresses andCountermeasures in Austenitic Steel Piping. International Conference onNuclear Engineering. 1997:25~29
21 汪建华, 戚新海, 钟小敏. 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
22 J.A. Goldak. Error Due to Two Dimensional Approximation in Heat TransferAnalysis of Welding. Welding Journal.1993,72(9):440~446
23 S. Brown, H. Song. Finite Element Simulation of Welding of LargeStructures. Journal of Engineering for Industry Transactions of ASME.1992,114(4):441~451
24 P.S. Wei, W.H. Giedt. Surface Tension Gradient – Driven Flow around anElectron Beam Welding Cavity. Welding Journal. 1985,64(9):251~259
25 Z.C. Lin, W.C. Pan. A Coupled Thermo-elastic-plastic Model with aModified Direct Interaction Method In a Cold Extrusion Process. Journal ofStrain Analysis. 1993,128(2): 89~100
26 Y. Ueda. Analysis of the Thermal Elastic-plastic Stress and Strain duringWelding. Trans. Japan Welding Soc.. 1971,2(2):90~100
27 H.D. Hibbitt, P.V. Marcal. A Numerical Thermo-mechanical Model for theWelding and Subsequent Loading of a Fabricated Structure. Computer&Structure. 1973,3(5):1145~1174
28 K. Masubuchi. Prediction and Control of Residual Stresses and Distortion inWelded Structures. Proc. Theoretical Prediction in Joining and Welding.1996:71~88
29 Goldak J. Thermal Stress Analysis of Welds. From Melting Point to RoomTemperature. Proc. Theoretical Prediction in Joining and Welding.1996:225~230
30 L. Karlsson. Thermo-mechanical FE-analysis of Residual Stresses and StressRedistribution in Butt Welding of a Copper Canister for Spent Nuclear Fuel.Nuclear Engineering and Design. 2002,212(1):401~408
31 N.Nasstrom. Combined 3-D and Shell Modeling of Welding. Proc. IUTAMSymposium on the Mechanical Effects of Welding. Lulea, Sweden, Germany,1992:197~206
32 J.B.Leblond. A Theoretical and Numerical Approach to the Plastic BehaviorofSteelsduringPhaseTransformations.J.Mech.Phys.Solids.1986,34(4):395~409
33 Y.Ueda, K.Nakacho. Theory of Thermal Elastic-plastic Analysis with a MoreGeneral Work Harding Rule. Transaction of JWRI. 1980, 19(1):107~114
34 J.Argyris, J.Simmat. Computational Aspects of Welding Stress Analysis.Computer Meth. Appl.Mech&Eng. 1982, 133(4):625~666
35 B. Anderson. Thermal Stress in Large Butt-welded Plates. Journal of ThermalStress. 1981, (4):492~500
36 Ф.Grong. Metallurgical Modeling of Welding. The Institute of Materials.1994:56~60
37 Tso-Liang Teng, Chin-Ping Fung, Peng-Hsiang Chang, Wei-Chun Yang.Ananlysis of Residual Stresses and Distortions in T-joint Fillet Welds.International Journal of Pressure Vessels and Piping. 2001,78:523~538
38 薛小龙, 桑芝富, 朱加贵. 多道间断焊 T 型接头的数值模拟. 设计计算.2004,11(21):27~31
39 唐慕尧. 单面焊时终端裂纹的研究. 焊接学报. 1987,7(3):123~132
40 陈楚. 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
41 汪建华. 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. 西安, 1990:209~212
42 汪建华 . 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
43 J. Wang. Improvement in Numerical Accuracy and Stability of 3-D FEMAnalysis in Welding. Welding Journal. 1996,75(4):129~134
44 汪建华. 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
45 汪建华. 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
46 赵海燕, 鹿安理, 史清宇. 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
47 鹿安理, 史静, 赵海燕. 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(2):201~205
48 史清宇. 焊接过程三维数值模拟的研究及应用. 清华大学博士学位论文.2000:40~90
49 田锡唐. 焊接结构. 机械工业出版社, 1981:17~46
50 刘庄. 热处理过程的数值模拟. 科学出版社, 1996:58~59