高速列车铝合金车体焊接构件残余应力数值模拟
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摘要
随着我国高速铁路的快速发展,高速列车的速度不断的提升,高速列车的生产质量要求也相应的提高。焊接作为高速列车生产的重要手段,焊接残余应力和残余变形一直是生产过程面临的难题,焊接残余变形不仅会影响列车外形的美观,而且会导致车体装配尺寸出现偏差；焊接残余应力对列车的疲劳强度有较大的影响。因此,掌握铝合金焊接残余应力和残余变形规律可以为设计、生产提供帮助。
本文使用SYSWELD有限元软件,对某型号的高速列车铝合金车体进行焊接模拟。铝合金车体是由底架、侧墙、车顶等结构组成,使用的材料为A5083P-O、A6N01 S-T5、A7N01S-T4、A7N01S-T5。.在进行焊接模拟过程中,需要提供四种材料的性能参数,如果通过实验测试材料性能参数,所需要的成本较高。因此,本文使用JMatPro4.1软件对四种材料进行计算,并利用获得的不同温度下材料参数建立铝合金材料数据库。通过对铝合金车体构件温度场模拟,获得焊接过程中热量的变化规律及构件经历的热循环曲线,为应力场分析提供依据。利用SYSWELD软件对铝合金车体构件在现有焊接工艺下进行应力场模拟,结合实际测试结果分析焊接残余应力的分布规律。计算结果显示铝合金焊接残余应力的最大值出现在焊缝及近缝区,大小为材料屈服强度的0.6-0.8。改变焊接顺序和约束载荷,分析两者对应力场的影响。
With the rapid development of high-speed railway in China, the high-speed train speed is continuously increasing. As a result, the production of high-speed train is Corresponding improved in quality requirements. Welding was regarded as an important means of high-speed train production; the welding residual stress and residual deformation have been a difficult issue in the Production process. Not only does residual deformation of the train affect the appearance of shape, but also it will result in deviation of the body assembly dimensions. Welding residual stress on fatigue strength of the train has a greater impact. Therefore, mastering the alloy welding residual stress and residual deformation can provide help for the design and the production.
The S YSWELD software was used in this article. It was used for a type of high-speed train simulation of welding aluminum alloy body. Aluminum body is formed by a chassis, side walls and a roof. The materials used are the A5083P-O, A6N01S-T5, A7N01S-T4 and A7N01S-T5. During the welding simulation, the performance parameters of these materials were needed. If the material properties were tested by experiments, it would need the high cost. Therefore, the JMatPro4.1 software was use to calculate these four materials properties in this article and the materials obtained at different temperatures were used to establish parameters of aluminum alloy material database. The variation of heat obtained in the Welding process and thermal cycling curves of components obtained, provided the basis for the stress field analysis through the simulation of temperature field of aluminum body components. Under the existing welding process, the aluminum alloy bodywork component has been simulated stress with SYSWELD software, and analysis welding residual stress distribution rule combining with actual simulated stress. Calculation results show that the maximum of aluminum alloy welding residual stress is in the weld seam appear near and area, and the size is 0.6 to 0.8 for material yield strength. Change the welding sequence and constraint load, and analyzed the influence to the stress field.
本文使用SYSWELD有限元软件,对某型号的高速列车铝合金车体进行焊接模拟。铝合金车体是由底架、侧墙、车顶等结构组成,使用的材料为A5083P-O、A6N01 S-T5、A7N01S-T4、A7N01S-T5。.在进行焊接模拟过程中,需要提供四种材料的性能参数,如果通过实验测试材料性能参数,所需要的成本较高。因此,本文使用JMatPro4.1软件对四种材料进行计算,并利用获得的不同温度下材料参数建立铝合金材料数据库。通过对铝合金车体构件温度场模拟,获得焊接过程中热量的变化规律及构件经历的热循环曲线,为应力场分析提供依据。利用SYSWELD软件对铝合金车体构件在现有焊接工艺下进行应力场模拟,结合实际测试结果分析焊接残余应力的分布规律。计算结果显示铝合金焊接残余应力的最大值出现在焊缝及近缝区,大小为材料屈服强度的0.6-0.8。改变焊接顺序和约束载荷,分析两者对应力场的影响。
With the rapid development of high-speed railway in China, the high-speed train speed is continuously increasing. As a result, the production of high-speed train is Corresponding improved in quality requirements. Welding was regarded as an important means of high-speed train production; the welding residual stress and residual deformation have been a difficult issue in the Production process. Not only does residual deformation of the train affect the appearance of shape, but also it will result in deviation of the body assembly dimensions. Welding residual stress on fatigue strength of the train has a greater impact. Therefore, mastering the alloy welding residual stress and residual deformation can provide help for the design and the production.
The S YSWELD software was used in this article. It was used for a type of high-speed train simulation of welding aluminum alloy body. Aluminum body is formed by a chassis, side walls and a roof. The materials used are the A5083P-O, A6N01S-T5, A7N01S-T4 and A7N01S-T5. During the welding simulation, the performance parameters of these materials were needed. If the material properties were tested by experiments, it would need the high cost. Therefore, the JMatPro4.1 software was use to calculate these four materials properties in this article and the materials obtained at different temperatures were used to establish parameters of aluminum alloy material database. The variation of heat obtained in the Welding process and thermal cycling curves of components obtained, provided the basis for the stress field analysis through the simulation of temperature field of aluminum body components. Under the existing welding process, the aluminum alloy bodywork component has been simulated stress with SYSWELD software, and analysis welding residual stress distribution rule combining with actual simulated stress. Calculation results show that the maximum of aluminum alloy welding residual stress is in the weld seam appear near and area, and the size is 0.6 to 0.8 for material yield strength. Change the welding sequence and constraint load, and analyzed the influence to the stress field.
引文
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[2]李世斌574.8km/h:V150高速列车创世界新纪录.郑铁科技通讯.2007.3
[3]周万盛,姚君山.铝及铝合金的焊接.北京：机械工业出版社,2006
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[5]薛淳,方鸣.中国和谐号CRH动车组.中国科技投资.2008,12：36-38
[6]汪建华.焊接数值模拟技术及其应用.上海交通大学出版社,2003
[7]陈丙森.计算机辅助焊接技术.北京：机械工业出版社,1999
[8]周建新,李栋才,徐宏伟.焊接残余应力数值模拟的研究与发展.金属成形工艺,2003(21)62-64
[9]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)：5-7
[10]吴言高,李午申,邹宏伟,冯灵芝.焊接模拟技术发展现状.焊接学报,2002(23)：89-92.
[11]冯小慧,许国英,郑小玫.金属材料在高速列车上的应用.金属世界.1995.02
[12]肖彦君,杨润栋.地铁车辆车体材料的选型分析.现代城市轨道交通.2005(1)：12-14
[13]刘静安,谢水生.铝合金材料的应用与技术开发.北京：冶金工业出版社,2004
[14]张卫华,王伯铭.中国高速列车创新发展.机车电传动.2010(1)：8-12
[15]李芾,安琪.国内外高速动车组的发展.电力机车与城轨车辆.2007,30(5)
[16]中国铁道百科全书机车车辆与电气化.北京：中国铁道出版社,2006
[17]王炎金.铝合金车体焊接工艺.北京：机械工业出版社,2009.12
[18]宋天民.残余应力的产生与消除.中国石油出版社,2004
[19]D.达拉伊著.焊接热效应、温度场、残余应力、变形.熊第京,郑朝云,史耀武译.北京：机械工业出版社,1997,7
[20]葛明兰,鲁家晟.焊接残余应力对焊接结构的影响.福建建筑,2010(7)50-52
[21]田锡唐.焊接结构.北京：机械工业出版社,1996
[22]中国机械工程学会焊接学会编.焊接手册：第3卷焊接结构.第二版.北京：机械工业出版社,2001
[23]CB3395-92残余应力测试方法钻孔应变释放法.
[24]王者昌.关于焊接残余应力消除原理的探讨.焊接学报,2000,21(2)：55-58
[25]张德芬,宋天民.振动时效的效果及机理综述.抚顺石油学院学报.2000.20
[26]李栋才.焊接应力.西安：陕西科学技术出版社,1999
[27]JMatPro User Guide,2005
[28]李霞,苏航,陈晓玲,杨才福,谢刚.材料数据库的现状与发展.中国冶金.2207.6(17)：5-8
[29]林钢,林慧国,赵玉涛.铝合金应用手册.北京：机械工业出版社,2006.1
[30]中国航空材料手册第3卷铝合金镁合金.第2版.北京：中国标准出版社,2001,12
[31]SYSWELD2006 Material Data Management. ESI Group.2006
[32]JIS H4000-2006铝和铝合金薄板材、带材和板材
[33]D.Price. A Guide to Material Database. Material,1993,1(7):418
[34]Nigel Saunders.The Application of Calculated Phase Equilibria to Multi-Component Aluminum Alloy. J.JILM 51(2001.3):141-150
[35]N.Saunder,X.Li,A.P.Miodownik,J.P.Schille. Modelling of The Thermo-Physical and Physical Properties for Solidification of Al-Alloys.ed. P.Crepeanl (Warrendale,PA:TMS,2003).999
[36]X.Cao,N.Saunders,J.Campbell. Effect Of Iron And Manganese Contents On Convection-Free Precipitation And Sedimentation Of Primarya-Al(FeMn)Si Phase In Liquid Al-11.5Si-0.4Mg Alloy. JOURNAL of Material Science.2004(39):2303-2314
[37]Goldak John. Chakravarti Aditya,Bibbv.Mlalcolm. A double ellipsoid finite element model for welding heat source[Z]. II WDoc,1985
[38]方总涛,唐德渝.焊接温度场及应力场数值模拟的研究进展.中国造船,2009(50)375-379
[39]莫春立,钱百年,国旭明,于少飞.焊接热源计算模式的研究进展.焊接学报,2001(22)：93-96.
[40]John Goldak. A New Finite Model for Welding Heat Source. Metallurgual. Transactions, 1984,15B (2):299-305
[41]蔡志鹏,赵海燕,鹿安理,史清宇.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,20023(13)：208-210
[42]张泽云,杨鑫华,王春生,杨德惠,兆文忠.构件焊接热源的仿真与应用.大连交通大学学报.2008,5(29)：95-98
[43]Visual-Mesh V3.5_Tutorials. ESI,2007,6
[44]李维特,黄保海,毕仲波.热应力理论分析及应用.北京：中国电力出版社,2004.
[45]华鹏,孙俊生.有限元软件SYSWELD在焊接数值模拟中的作用.山东机械2005,1
[46]焦立新.先进的焊接及热处理工艺仿真方案.航空制造技术.2007,12
[47]SYSWELD2008 Welding Simulation-User's Guide. ESI Group.2008
[48]The Welding Simulation Solution. ESI Group.2010
[49]Tso-Liang Teng. Peng-Hsiang Chang, Hsush-Chaok. Finite Element Analysis of Circular Path Welds. International Journal of Pressure Vessels and Piping.2000.77:643-650
[50]刘晓雪.焊接残余应力和残余变形分析的建模技术研究.硕士学位论文.2007,06
[51]佘昌莲.焊接结构的残余应力研究.硕士学位论文.2006,04
[52]张士林,任颂赞.简明铝合金手册.上海科学技术文献出版社.2006,9
[53]Handbook of Al Alloys. America
[2]李世斌574.8km/h:V150高速列车创世界新纪录.郑铁科技通讯.2007.3
[3]周万盛,姚君山.铝及铝合金的焊接.北京：机械工业出版社,2006
[4]钱立新.世界高速铁路技术.北京：中国铁道出版社,2003.
[5]薛淳,方鸣.中国和谐号CRH动车组.中国科技投资.2008,12：36-38
[6]汪建华.焊接数值模拟技术及其应用.上海交通大学出版社,2003
[7]陈丙森.计算机辅助焊接技术.北京：机械工业出版社,1999
[8]周建新,李栋才,徐宏伟.焊接残余应力数值模拟的研究与发展.金属成形工艺,2003(21)62-64
[9]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)：5-7
[10]吴言高,李午申,邹宏伟,冯灵芝.焊接模拟技术发展现状.焊接学报,2002(23)：89-92.
[11]冯小慧,许国英,郑小玫.金属材料在高速列车上的应用.金属世界.1995.02
[12]肖彦君,杨润栋.地铁车辆车体材料的选型分析.现代城市轨道交通.2005(1)：12-14
[13]刘静安,谢水生.铝合金材料的应用与技术开发.北京：冶金工业出版社,2004
[14]张卫华,王伯铭.中国高速列车创新发展.机车电传动.2010(1)：8-12
[15]李芾,安琪.国内外高速动车组的发展.电力机车与城轨车辆.2007,30(5)
[16]中国铁道百科全书机车车辆与电气化.北京：中国铁道出版社,2006
[17]王炎金.铝合金车体焊接工艺.北京：机械工业出版社,2009.12
[18]宋天民.残余应力的产生与消除.中国石油出版社,2004
[19]D.达拉伊著.焊接热效应、温度场、残余应力、变形.熊第京,郑朝云,史耀武译.北京：机械工业出版社,1997,7
[20]葛明兰,鲁家晟.焊接残余应力对焊接结构的影响.福建建筑,2010(7)50-52
[21]田锡唐.焊接结构.北京：机械工业出版社,1996
[22]中国机械工程学会焊接学会编.焊接手册：第3卷焊接结构.第二版.北京：机械工业出版社,2001
[23]CB3395-92残余应力测试方法钻孔应变释放法.
[24]王者昌.关于焊接残余应力消除原理的探讨.焊接学报,2000,21(2)：55-58
[25]张德芬,宋天民.振动时效的效果及机理综述.抚顺石油学院学报.2000.20
[26]李栋才.焊接应力.西安：陕西科学技术出版社,1999
[27]JMatPro User Guide,2005
[28]李霞,苏航,陈晓玲,杨才福,谢刚.材料数据库的现状与发展.中国冶金.2207.6(17)：5-8
[29]林钢,林慧国,赵玉涛.铝合金应用手册.北京：机械工业出版社,2006.1
[30]中国航空材料手册第3卷铝合金镁合金.第2版.北京：中国标准出版社,2001,12
[31]SYSWELD2006 Material Data Management. ESI Group.2006
[32]JIS H4000-2006铝和铝合金薄板材、带材和板材
[33]D.Price. A Guide to Material Database. Material,1993,1(7):418
[34]Nigel Saunders.The Application of Calculated Phase Equilibria to Multi-Component Aluminum Alloy. J.JILM 51(2001.3):141-150
[35]N.Saunder,X.Li,A.P.Miodownik,J.P.Schille. Modelling of The Thermo-Physical and Physical Properties for Solidification of Al-Alloys.ed. P.Crepeanl (Warrendale,PA:TMS,2003).999
[36]X.Cao,N.Saunders,J.Campbell. Effect Of Iron And Manganese Contents On Convection-Free Precipitation And Sedimentation Of Primarya-Al(FeMn)Si Phase In Liquid Al-11.5Si-0.4Mg Alloy. JOURNAL of Material Science.2004(39):2303-2314
[37]Goldak John. Chakravarti Aditya,Bibbv.Mlalcolm. A double ellipsoid finite element model for welding heat source[Z]. II WDoc,1985
[38]方总涛,唐德渝.焊接温度场及应力场数值模拟的研究进展.中国造船,2009(50)375-379
[39]莫春立,钱百年,国旭明,于少飞.焊接热源计算模式的研究进展.焊接学报,2001(22)：93-96.
[40]John Goldak. A New Finite Model for Welding Heat Source. Metallurgual. Transactions, 1984,15B (2):299-305
[41]蔡志鹏,赵海燕,鹿安理,史清宇.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,20023(13)：208-210
[42]张泽云,杨鑫华,王春生,杨德惠,兆文忠.构件焊接热源的仿真与应用.大连交通大学学报.2008,5(29)：95-98
[43]Visual-Mesh V3.5_Tutorials. ESI,2007,6
[44]李维特,黄保海,毕仲波.热应力理论分析及应用.北京：中国电力出版社,2004.
[45]华鹏,孙俊生.有限元软件SYSWELD在焊接数值模拟中的作用.山东机械2005,1
[46]焦立新.先进的焊接及热处理工艺仿真方案.航空制造技术.2007,12
[47]SYSWELD2008 Welding Simulation-User's Guide. ESI Group.2008
[48]The Welding Simulation Solution. ESI Group.2010
[49]Tso-Liang Teng. Peng-Hsiang Chang, Hsush-Chaok. Finite Element Analysis of Circular Path Welds. International Journal of Pressure Vessels and Piping.2000.77:643-650
[50]刘晓雪.焊接残余应力和残余变形分析的建模技术研究.硕士学位论文.2007,06
[51]佘昌莲.焊接结构的残余应力研究.硕士学位论文.2006,04
[52]张士林,任颂赞.简明铝合金手册.上海科学技术文献出版社.2006,9
[53]Handbook of Al Alloys. America