远程焊接数值模拟系统的研究
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摘要
随着科技的发展，计算机网络技术在各行业中的应用得到越来越大的重视。远程焊接数值模拟系统将计算机网络和智能处理技术应用到焊接数值模拟中，消除了焊接数值模拟在空间和技术上的限制，最大限度地利用企业现有软硬件资源，同时还降低了对使用者有限元专业技能的要求，对于焊接数值模拟的应用和发展具有重要意义。
本文首先对远程焊接数值模拟系统的结构进行了系统研究，提出了由应用层、表面层和执行层组成的三层逻辑结构及由前台数据处理模块、后台数据处理模块和有限元求解模块组成的三层物理结构；同时对典型焊接接头的二维有限元分析模型的建立及其几何模型、边界条件、初始条件及材料属性等组成部分进行了全面研究，并在此基础上提出了参数化建模方法，以映射的方式将实际数据处理为分析模型的组件，为焊接过程的计算机智能分析的实现提供了一个合理的数学基础。
利用以上研究结果，本课题结合数据库技术和EJB、JDBC及DBI技术开发了完整的远程焊接数值模拟系统，该系统能智能地对焊接条件数据进行分析并获取有限元分析生成的应力、应变场及其它结果的分布图。本课题还对系统的模板规范和扩展规范进行了研究，增强了系统的可扩展性。
针对系统的实用性及求解结果的正确性，本课题使用远程焊接数值模拟系统与常规有限元分析方法对平板对接和T形接头进行了对比模拟，对比结果表明，该系统可以实现远程化、智能化处理，计算结果具有合理性，并且能大幅度节省建模时间和降低操作人员的专业技术要求。
本文在焊接过程数值模拟的网络化和参数化方面的研究，实现了焊接数值模拟的远程化和智能化，这些创新性的研究对焊接加工行业实现网络化敏捷制造具有较大的借鉴价值和实用意义，并为其提供了一个可供参考的方法。
With the development of science and technology, the application of internet technology got more and more attentions. Remote Welding Numerical Simulation System applied the technology of computer internet and computer intelligence to the welding numerical simulation, eliminated the limit on space and knowledge, reached the maximum using of the existed resources in an enterprise, and cut down the requirement for FEM knowledge of users. It is of important meaning for the application and development of welding numerical simulation.
This paper researched the structure of the system roundly, and outlined the three-layer structure of the application layer, the session layer and the execution layer in logic, besides that, the paper planned the physical structure of the faced data module, the background data module and the FEM solution module.
Also, the 2D FEM analyzing model of the typical joint and its geometry model, boundary conditions, initial conditions and material properties were studied. Based on above, the parameter modeling method was brought forward, which transfers the real data to FEM modal with mapping, and provides a mathematic basis for computer's analyzing intelligently of welding process.
With the results of above researches, this paper developed the Remote Welding Numerical Simulation System by using the technology of database, EJB, JDBC, and DBI. The system has the capabilities of dealing with the real welding data intelligently, getting the distributing charts of the residual stress and strain automatically. In order to perfect the capability of extending, the criterions of coding template and extending were both studied.
To verify the practicability and validity of the system, this paper analyzed the butt joint and the T-joint with the two comparative methods of the Remote Welding Numerical Simulation System and the common FEM. The results showed that, the system has the abilities of intelligence and internet. And, with the reasonable result,
the system took fewer times and required less special knowledge of FEM.
The researches on the internet and parameter modeling method in this paper for the numerical simulation of welding realized the remote and the intelligence in the fields of welding numerical simulation. These innovational researches are important and valuable for the applications of the numerical simulation of the welding process in manufacturing fields.
本文首先对远程焊接数值模拟系统的结构进行了系统研究，提出了由应用层、表面层和执行层组成的三层逻辑结构及由前台数据处理模块、后台数据处理模块和有限元求解模块组成的三层物理结构；同时对典型焊接接头的二维有限元分析模型的建立及其几何模型、边界条件、初始条件及材料属性等组成部分进行了全面研究，并在此基础上提出了参数化建模方法，以映射的方式将实际数据处理为分析模型的组件，为焊接过程的计算机智能分析的实现提供了一个合理的数学基础。
利用以上研究结果，本课题结合数据库技术和EJB、JDBC及DBI技术开发了完整的远程焊接数值模拟系统，该系统能智能地对焊接条件数据进行分析并获取有限元分析生成的应力、应变场及其它结果的分布图。本课题还对系统的模板规范和扩展规范进行了研究，增强了系统的可扩展性。
针对系统的实用性及求解结果的正确性，本课题使用远程焊接数值模拟系统与常规有限元分析方法对平板对接和T形接头进行了对比模拟，对比结果表明，该系统可以实现远程化、智能化处理，计算结果具有合理性，并且能大幅度节省建模时间和降低操作人员的专业技术要求。
本文在焊接过程数值模拟的网络化和参数化方面的研究，实现了焊接数值模拟的远程化和智能化，这些创新性的研究对焊接加工行业实现网络化敏捷制造具有较大的借鉴价值和实用意义，并为其提供了一个可供参考的方法。
With the development of science and technology, the application of internet technology got more and more attentions. Remote Welding Numerical Simulation System applied the technology of computer internet and computer intelligence to the welding numerical simulation, eliminated the limit on space and knowledge, reached the maximum using of the existed resources in an enterprise, and cut down the requirement for FEM knowledge of users. It is of important meaning for the application and development of welding numerical simulation.
This paper researched the structure of the system roundly, and outlined the three-layer structure of the application layer, the session layer and the execution layer in logic, besides that, the paper planned the physical structure of the faced data module, the background data module and the FEM solution module.
Also, the 2D FEM analyzing model of the typical joint and its geometry model, boundary conditions, initial conditions and material properties were studied. Based on above, the parameter modeling method was brought forward, which transfers the real data to FEM modal with mapping, and provides a mathematic basis for computer's analyzing intelligently of welding process.
With the results of above researches, this paper developed the Remote Welding Numerical Simulation System by using the technology of database, EJB, JDBC, and DBI. The system has the capabilities of dealing with the real welding data intelligently, getting the distributing charts of the residual stress and strain automatically. In order to perfect the capability of extending, the criterions of coding template and extending were both studied.
To verify the practicability and validity of the system, this paper analyzed the butt joint and the T-joint with the two comparative methods of the Remote Welding Numerical Simulation System and the common FEM. The results showed that, the system has the abilities of intelligence and internet. And, with the reasonable result,
the system took fewer times and required less special knowledge of FEM.
The researches on the internet and parameter modeling method in this paper for the numerical simulation of welding realized the remote and the intelligence in the fields of welding numerical simulation. These innovational researches are important and valuable for the applications of the numerical simulation of the welding process in manufacturing fields.
引文
[1] Roger Nagal，Rick Dove．21st Century Manufacturing Enterprise strategy: An Industry-Led View & Infrastructure．Iacocca Institute，Lehigh Universigy，1991
[2] 宋天虎．先进制造技术的未来与发展．中国机械工程，1998，9(8)：2~5
[3] Abair Robert A．Agile manufacturing: this is not just repackaging of material requirements planning and just-in-time．Annual International Conference Proceedings - American Production and Inventory Control Society，1995，10: 196~198
[4] Martinez M T，Fouletier P，Park K H．Virtual enterprise - Organisation, evolution and control．International Journal of Production Economics，2001，12，74 (1-3): 225~238
[5] 张书亭，杨建军，邹学礼．面向敏捷制造车间的制造执行系统．新技术新工艺，2000，12: 2~4
[6] Adamyan Angela，He David．Failure and safety assessment of systems using Petri nets．Proceedings - IEEE International Conference on Robotics and Automation，2002，5: 1919-1924
[7] Coronado M A E，Sarhadi M，Millar C．Defining a framework for information systems requirements for agile manufacturing．International Journal of Production Economics，2002，10，75(1-2): 57-68
[8] Frayret J M，D'Amours S，Montreuil B，et al．A network approach to operate agile manufacturing systems．International Journal of Production Economics，2001，12，74(1-3): 239~259
[9] 张曙．分散网络化制造．机械与电子，1998，(5):3
[10] 陈晓川，刘晓冰，张暴暴，等．分布式网络化研究中心及其在敏捷制造中的应用．机械与电子，1999，(5):15
[11] Whiteside，Robert A．Pancerella，Carmen M．Klevgard，Paul A．CORBA-based manufacturing environment．Proceedings of the Hawaii International Conference on System Sciences，1997，1:34
[12] 武振业，王志兵．面向敏捷制造的可视化团体决策系统的设计．计算机应用研究，2000，3:9
[13] Monplaisir，Leslie F．Riordan，Catherine Benjamin，Colin O．Comparison of intelligent CSCW architectures for the evaluation of agile manufacturing systems designs．Human Factors and Ergonomics In Manufacturing，1999，9，(2):137
[14] 林华，王宏典，张友良．MCSDM:一个面向敏捷制造的CSCW系统．计算机工程与科学，1998，20，(2):51
[15] D．Rosenthal，H．Schmenber，Thermal Study of Arc Welding．Welding Journal，1938，17(4): 2
[16] D．Rosenthal，Mathematical Theory of Heat Distrbution during Welding and Cuttin．Welding Journal，1941，20(5):220
[17] H．H．雷卡林．焊接热过程计算．计算机械工业出版社，1958，5:2
[18] Q，I，Shpigunova; S，V，Shpigunov; Yu，N，Saraev; et al．Mathematical simulation of heat and mass transfer in pulsed arc welding of root welds by melting electrode．Acta Metallurgica Sinica，2000，13(1): 56~63
[19] 武传松．焊接热过程数值分析．哈尔滨：哈尔滨工业大学出版社，1990．1
[20] 赵海燕，鹿安理等，焊接过程数值模拟中的分段移动热源．计算机在焊接中的应用技术交流会论文集，2000，11:125
[21] 史清宇．焊接过程三位数值模拟的研究及应用：[清华大学博士论文]．北京：清华大学机械工程系，2000
[22] Z，Paley; P，D，Hibbert．Computation of temperatures in actual weld designs．Welding Journal，1975，54(11):385~392
[23] 吴爱萍，任家烈，鹿安理．辅助冷、热源防止焊缝凝固裂纹的研究．航空材料学报，1996，3，16(1):38
[24] 魏艳红，刘仁培，董祖珏．不锈钢焊接凝固裂纹温度场的数值模拟．焊接学报，1999，9，20(3):199
[25] 龙昕，汪建华，等．电阻点焊电极温度场分布的数值模拟．计算机在焊接中的应用技术交流会论文集，2000，11:100
[26] 蔡洪能，唐慕尧．TIG焊接温度场的有限元分析．焊管，1995，18(1): 21~65
[27] Z Paley，P D Hibbort．Computation of Temperature in Actual Weld Designs．Welding Journal，1975，54(3):12
[28] J Frankel，A Abbate，W Scholz．The Effect of Residual Stress on Hardness Measurements，Experimental Mechanicsm，1993，1: 164
[29] Mather J．Determination of Initial Stress by Messuring the Deformation Around Drilled Hole，1934，56:245
[30] M Kovac，Method for Residual Stress Measurement in Welded Seams．Journal of Materials Processing Technology，1995，52(4):503
[31] J M Blackbum，P C Brand，H J Prask，et al．Importance of d//o in the Determination of Weld Residual Stresses Usiing Neutron Diffraction．Proceedings of The TMS Materials Week'95 Symposium
[32] 吴爱萍，任家烈，鹿安理．焊缝凝固时的应力应变过程分析．航空材料学报，1993，9，13(3):36
[33] 吴爱萍，彭真山，等．陶瓷与金属钎焊复合结构应力与变形的有限元分析与控制．计算机在焊接中的应用技术交流会论文集，2000，11:110
[34] P Takriwal，J Mazumber．Transient and Residual Strain-Stress Analysis of GMAW．Journal of Engineering Materials and Technology，1991，113(3):336
[35] M Y Tang，F S Meng．Adjustmeng of Residual Stress Field of Multi-LayerGirth -Welding Join．Journal of Xi'an Jiaotong University，1994，28(4):97
[36] 鹿安理，史清宇，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．中国机械工程，2002，12(2): 183~187
[37] 魏良武，汪建华．液力变矩器焊接变形与应力分析及有限元模拟．计算机在焊接中的应用技术交流会论文集，2000，11:188
[38] Sarkani，Shahram．Efficient approach for computing residual stresses in welded joints．Finite Elements in Analysis and Design，2000，35(3): 247~268
[39] Brown S，Song H．Finite element simulation of welding of large structures．Journal of Engineering for Industry，Transactions of the ASME，1992，114(4): 441~451
[40] K Masubuchi．Prediction and control of residual stresses and distortion in welded structures．Proceedings of the international symposium on theoretical prediction in joining and welding．Osaka，Japan，1996: 71-88
[41] 赵海燕，鹿安理，史清宇，等．T型接头焊接过程的数值模拟．第三届材料与热加工物理模拟及数值模拟国际学术会议论文集．北京: 1999: 118~124
[42] 蔡志鹏，赵海燕，鹿安理．焊接温度场、应力场和应变场相似准则的推导及验证．中国机械工程，2001，12(10):1165~1169
[43] 任维佳．大型电机转子焊接残余应力的数值模拟研究：[清华大学硕士论文]．北京：清华大学机械工程系，2001
[44] 田锡唐．焊接结构．北京：机械工业出版社，1997，10
[45] MARC Analysis Research Corporation．温度场及其耦合场的有限元分析．MARC中国．北京：MARC中国公司，1998-01
[46] 王勖成，邵敏．有限单元法基本原理和数值方法．北京：清华大学出版社，1997
[47] [德]D．拉达伊．焊接热效应、残余应力、变形．机械工业出版社，1997．7
[48] 机械工程材料性能数据手册．北京：机械工业出版社，1994．11
[49] 陈家祥．炼钢常用图表数据手册．北京：冶金工业出版社，1984．11
[50] 张家荣，赵廷元．工程常用物质的热物理性质手册．北京：新时代出版社，1987．9
[51] 马庆芳．实用热物理性能手册．北京：中国农业机械出版社，1986．1
[52] 吴德海，任家烈，陈森灿．近代材料加工原理．北京：清华大学出版社，1997．3
[2] 宋天虎．先进制造技术的未来与发展．中国机械工程，1998，9(8)：2~5
[3] Abair Robert A．Agile manufacturing: this is not just repackaging of material requirements planning and just-in-time．Annual International Conference Proceedings - American Production and Inventory Control Society，1995，10: 196~198
[4] Martinez M T，Fouletier P，Park K H．Virtual enterprise - Organisation, evolution and control．International Journal of Production Economics，2001，12，74 (1-3): 225~238
[5] 张书亭，杨建军，邹学礼．面向敏捷制造车间的制造执行系统．新技术新工艺，2000，12: 2~4
[6] Adamyan Angela，He David．Failure and safety assessment of systems using Petri nets．Proceedings - IEEE International Conference on Robotics and Automation，2002，5: 1919-1924
[7] Coronado M A E，Sarhadi M，Millar C．Defining a framework for information systems requirements for agile manufacturing．International Journal of Production Economics，2002，10，75(1-2): 57-68
[8] Frayret J M，D'Amours S，Montreuil B，et al．A network approach to operate agile manufacturing systems．International Journal of Production Economics，2001，12，74(1-3): 239~259
[9] 张曙．分散网络化制造．机械与电子，1998，(5):3
[10] 陈晓川，刘晓冰，张暴暴，等．分布式网络化研究中心及其在敏捷制造中的应用．机械与电子，1999，(5):15
[11] Whiteside，Robert A．Pancerella，Carmen M．Klevgard，Paul A．CORBA-based manufacturing environment．Proceedings of the Hawaii International Conference on System Sciences，1997，1:34
[12] 武振业，王志兵．面向敏捷制造的可视化团体决策系统的设计．计算机应用研究，2000，3:9
[13] Monplaisir，Leslie F．Riordan，Catherine Benjamin，Colin O．Comparison of intelligent CSCW architectures for the evaluation of agile manufacturing systems designs．Human Factors and Ergonomics In Manufacturing，1999，9，(2):137
[14] 林华，王宏典，张友良．MCSDM:一个面向敏捷制造的CSCW系统．计算机工程与科学，1998，20，(2):51
[15] D．Rosenthal，H．Schmenber，Thermal Study of Arc Welding．Welding Journal，1938，17(4): 2
[16] D．Rosenthal，Mathematical Theory of Heat Distrbution during Welding and Cuttin．Welding Journal，1941，20(5):220
[17] H．H．雷卡林．焊接热过程计算．计算机械工业出版社，1958，5:2
[18] Q，I，Shpigunova; S，V，Shpigunov; Yu，N，Saraev; et al．Mathematical simulation of heat and mass transfer in pulsed arc welding of root welds by melting electrode．Acta Metallurgica Sinica，2000，13(1): 56~63
[19] 武传松．焊接热过程数值分析．哈尔滨：哈尔滨工业大学出版社，1990．1
[20] 赵海燕，鹿安理等，焊接过程数值模拟中的分段移动热源．计算机在焊接中的应用技术交流会论文集，2000，11:125
[21] 史清宇．焊接过程三位数值模拟的研究及应用：[清华大学博士论文]．北京：清华大学机械工程系，2000
[22] Z，Paley; P，D，Hibbert．Computation of temperatures in actual weld designs．Welding Journal，1975，54(11):385~392
[23] 吴爱萍，任家烈，鹿安理．辅助冷、热源防止焊缝凝固裂纹的研究．航空材料学报，1996，3，16(1):38
[24] 魏艳红，刘仁培，董祖珏．不锈钢焊接凝固裂纹温度场的数值模拟．焊接学报，1999，9，20(3):199
[25] 龙昕，汪建华，等．电阻点焊电极温度场分布的数值模拟．计算机在焊接中的应用技术交流会论文集，2000，11:100
[26] 蔡洪能，唐慕尧．TIG焊接温度场的有限元分析．焊管，1995，18(1): 21~65
[27] Z Paley，P D Hibbort．Computation of Temperature in Actual Weld Designs．Welding Journal，1975，54(3):12
[28] J Frankel，A Abbate，W Scholz．The Effect of Residual Stress on Hardness Measurements，Experimental Mechanicsm，1993，1: 164
[29] Mather J．Determination of Initial Stress by Messuring the Deformation Around Drilled Hole，1934，56:245
[30] M Kovac，Method for Residual Stress Measurement in Welded Seams．Journal of Materials Processing Technology，1995，52(4):503
[31] J M Blackbum，P C Brand，H J Prask，et al．Importance of d//o in the Determination of Weld Residual Stresses Usiing Neutron Diffraction．Proceedings of The TMS Materials Week'95 Symposium
[32] 吴爱萍，任家烈，鹿安理．焊缝凝固时的应力应变过程分析．航空材料学报，1993，9，13(3):36
[33] 吴爱萍，彭真山，等．陶瓷与金属钎焊复合结构应力与变形的有限元分析与控制．计算机在焊接中的应用技术交流会论文集，2000，11:110
[34] P Takriwal，J Mazumber．Transient and Residual Strain-Stress Analysis of GMAW．Journal of Engineering Materials and Technology，1991，113(3):336
[35] M Y Tang，F S Meng．Adjustmeng of Residual Stress Field of Multi-LayerGirth -Welding Join．Journal of Xi'an Jiaotong University，1994，28(4):97
[36] 鹿安理，史清宇，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．中国机械工程，2002，12(2): 183~187
[37] 魏良武，汪建华．液力变矩器焊接变形与应力分析及有限元模拟．计算机在焊接中的应用技术交流会论文集，2000，11:188
[38] Sarkani，Shahram．Efficient approach for computing residual stresses in welded joints．Finite Elements in Analysis and Design，2000，35(3): 247~268
[39] Brown S，Song H．Finite element simulation of welding of large structures．Journal of Engineering for Industry，Transactions of the ASME，1992，114(4): 441~451
[40] K Masubuchi．Prediction and control of residual stresses and distortion in welded structures．Proceedings of the international symposium on theoretical prediction in joining and welding．Osaka，Japan，1996: 71-88
[41] 赵海燕，鹿安理，史清宇，等．T型接头焊接过程的数值模拟．第三届材料与热加工物理模拟及数值模拟国际学术会议论文集．北京: 1999: 118~124
[42] 蔡志鹏，赵海燕，鹿安理．焊接温度场、应力场和应变场相似准则的推导及验证．中国机械工程，2001，12(10):1165~1169
[43] 任维佳．大型电机转子焊接残余应力的数值模拟研究：[清华大学硕士论文]．北京：清华大学机械工程系，2001
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