桥式起重机箱型主梁的优化设计和焊接数值模拟
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摘要
起重机械是现代化生产中必不可少的运输工具。目前国内的桥式起重机,其结构尺寸一般都较国外同型号同吨位产品大许多,产生材料浪费问题。其原因除材料上有差别外,主要是结构设计不同造成的,因此首先对桥式起重机主梁结构进行分析,并提出了优化设计方案,减少了材料浪费。
起重机主梁作为焊接钢结构,在其制造过程中,焊接工艺占很大的比重。如果焊接工艺设计不适当,焊接残余变形有可能导致拱度不足,甚至引起下挠,这会严重影响起重机的安全运行,对人身和财产安全造成危害。为此,又对桥式起重机主梁结构的焊接过程进行研究,采用数值模拟分析了焊接工艺参数对起重机主梁挠度的影响。
为实现以上目的,首先利用ANSYS软件,在桥式起重机起重量和跨度一定情况下,对箱型主梁进行结构分析,并采用其中的优化程序对主梁进行优化设计,以达到在满足强度、刚度的前提下耗材最少的目的,得出了主梁的最优化设计结果,重量减轻了27%,效果明显;然后采用热力耦合及生死单元技术,选取分段移动串热源模型,对L型钢板进行焊接模拟,并给予实验验证;在此基础上按优化后的主梁结构尺寸建立主梁模型,进行了主梁盖板和腹板的焊接模拟,分析了焊接顺序对主梁挠度的影响,并进行了理论计算比较,这对主梁腹板下料时的拱度预置有很好的指导意义。
Lifting machinery is essential for modern production as means of transport. The domestic bridge cranes’structure sizes are generally larger than the foreign products with the same model and the same tonnage. In addition to the difference of materials, the structural differences in size are the main reason. To reduce material waste, the studies of girder’s structure analysis and optimal design are proposed.
The girder of crane is a structure of welded steel, whose welding process accounts for a large proportion in manufacturing process. If welding process programming is unreasonable, welding residual strain may lead to inadequate camber, or even cause the deflection, which will affect the safe operation of cranes seriously, and lead to the personal and property safety hazard. So the welding process is studied and the effect of the welding parameters on the deflection of crane girder is analyzed by numerical simulation.
In the condition of certain weight and span of bridge crane’s girder, ANSYS finite element analysis software for structural analysis and procedures to optimize the design of girder are adopted. In order to achieve the least consumables under the premise of meeting the strength and stiffness, a optimal design result is obtained. It is lightened by 27 percent; Then, the welding of L-plate is simulated by moving segmented heat source model and adopting coupled thermo-mechanical and life and death cell technology, which is verified through experimental study. According to the optimized size, the model of crane’s girder is established to simulated the welding of lap and web of girder. The affect of welding sequence on the deflection is analyzed and comparison of theoretical calculations is carried out, which is a valuable guide for the pre-camber when the web is cut.
起重机主梁作为焊接钢结构,在其制造过程中,焊接工艺占很大的比重。如果焊接工艺设计不适当,焊接残余变形有可能导致拱度不足,甚至引起下挠,这会严重影响起重机的安全运行,对人身和财产安全造成危害。为此,又对桥式起重机主梁结构的焊接过程进行研究,采用数值模拟分析了焊接工艺参数对起重机主梁挠度的影响。
为实现以上目的,首先利用ANSYS软件,在桥式起重机起重量和跨度一定情况下,对箱型主梁进行结构分析,并采用其中的优化程序对主梁进行优化设计,以达到在满足强度、刚度的前提下耗材最少的目的,得出了主梁的最优化设计结果,重量减轻了27%,效果明显;然后采用热力耦合及生死单元技术,选取分段移动串热源模型,对L型钢板进行焊接模拟,并给予实验验证;在此基础上按优化后的主梁结构尺寸建立主梁模型,进行了主梁盖板和腹板的焊接模拟,分析了焊接顺序对主梁挠度的影响,并进行了理论计算比较,这对主梁腹板下料时的拱度预置有很好的指导意义。
Lifting machinery is essential for modern production as means of transport. The domestic bridge cranes’structure sizes are generally larger than the foreign products with the same model and the same tonnage. In addition to the difference of materials, the structural differences in size are the main reason. To reduce material waste, the studies of girder’s structure analysis and optimal design are proposed.
The girder of crane is a structure of welded steel, whose welding process accounts for a large proportion in manufacturing process. If welding process programming is unreasonable, welding residual strain may lead to inadequate camber, or even cause the deflection, which will affect the safe operation of cranes seriously, and lead to the personal and property safety hazard. So the welding process is studied and the effect of the welding parameters on the deflection of crane girder is analyzed by numerical simulation.
In the condition of certain weight and span of bridge crane’s girder, ANSYS finite element analysis software for structural analysis and procedures to optimize the design of girder are adopted. In order to achieve the least consumables under the premise of meeting the strength and stiffness, a optimal design result is obtained. It is lightened by 27 percent; Then, the welding of L-plate is simulated by moving segmented heat source model and adopting coupled thermo-mechanical and life and death cell technology, which is verified through experimental study. According to the optimized size, the model of crane’s girder is established to simulated the welding of lap and web of girder. The affect of welding sequence on the deflection is analyzed and comparison of theoretical calculations is carried out, which is a valuable guide for the pre-camber when the web is cut.
引文
1陈玮璋.起重机金属结构.北京:人民交通出版社,1988
2张芸.桥式起重机常见机械故障分析及预防措施.科技信息,2009,(7):486
3须雷.现代起重机的特征和发展动态.起重运输机械,1997,(10):3-7
4王国强.现代设计技术.北京:化学工业出版社,2006
5 Q.J.PENG, C.S.YU. Enhanced Integrated Manufacturing Systems in an Immersive Virtual Environment. Journal of Engineering Manufacture. 2007,221(83):447-487
6田锡唐.焊接结构.北京:机械工业出版社,1982
7增援兴一.焊接结构分析.北京:机械工业出版社,1983:158-161
8贾安东.焊接结构与生产.第2版.北京:机械工业出版社,2007
9潘际蜜.展望21世纪焊接科研.中国机械工程,2000,11(2):23-25
10张朝晖.ANSYS8.0结构分析及实例解析.北京:机械工业出版社,2005
11樊杰,赵轶,徐清浩.有限元法的一般思想.科技情报开发与经济.2008,18(3):157-158
12吕召会.有限元法在工程设计中的应用.电子机械工程.2005,21(4):59-60
13谢江波,刘亚青,张鹏飞.有限元方法概述.设计与研究.2007,(5):29-30
14徐小波.塑性成型的刚塑性有限元方法概述.中国水运(理论版),2006,4(4):102-103
15郝伟,张洪,郝永福.有限元方法在接触问题中的应用.机械管理开发,2005,(2):49
16 W.C.A.THACKER, Brief Review of Methods Used for Generating Irregular Computational Grids. International Journal for Numerical Method in Engineering, 1980,(15):1335-1341
17 H.O.LEK. Finite Element Mesh Generation Methods. A Review and Classification. Computer Aided Design, 1988,20(1):27-38
18王焕定,焦兆平.有限单元法基础.北京:高等教育出版社,2002
19傅永华.有限元分析基础.武汉:武汉大学出版社,2003
20叶绍松,阮祥发,赵燕.有限元法在结构分析中的应用.机械研究与应用.2005,18(4):8-9
21赵经文,王宏钰.结构有限元分析.北京:科学出版社,2001
22 ANSYS, Inc. ANSYS Tutorials for Release5.4.Forth Edition. SAS, IP Inc. 1997
23 ANSYS, Inc. ANSYS Analysis Guides First Edition. SAS, IP Inc. 1997
24 ANSYS, Inc. ANSYS Commands Reference. Ninth Edition. SAS, IP Inc. 1997
25 ANSYS, Inc. ANSYS Elements Reference. Ninth Edition. SAS, IP Inc. 1997
26停永华,陈定方.起重机结构件加筋对结构强度与刚度的影响.起重运输机械,1996(5):30-31
27王小慧,程文明,杨春松,等.起重机金属结构有限元分析的模型处理技术.起重运输机械, 2006(9):33-34
28谭建国.使用ANSYS 6.0进行有限元分析.北京:北京大学出版社,2002
29 E.J.HAUG, J.S.ARORA. Applied Optimal Design. Awiley Interseienee Publieation, 1979
30 R.J. AGUILAR. Systems Analysis and Design. Preniice-HallIne.Englewood, Cliffs N.J. 1973
31 P.E.GILL, W.MURRAY. Wright M H. Practical Optimization, Academic Press Inc London: LTD, 1981
32祝磊,马赢.ANSYS7.0入门与提高.北京:清华大学出版社,2004:3
33 ANSYS, Inc. ANSYS Advanced Optimazation Nson Analysis System, Inc. 1994
34起重机设计规范修订组,起重机设计规范(GB3811-2008).北京:中国标准出版社,2008
35刘兴龙,曲仕尧,邹增大等.基于ANSYS的焊接过程有限元模拟.电焊机.2007(7):41-43
36黄开文.国外高钢级管线钢的研究与使用情况.焊管,2003,26(3):1-10
37 Y.SHAH. Computational Trends in Engineering Simulation. In MCAE’97 International Seminar, Beijing, 1997:8-10
38汪建华,戚新海,钟小敏.三维瞬态焊接温度场的有限元模拟.上海交通大学学报,1996,30(3):121-125
39陈丙森.计算机辅助焊接技术北京机械工业出版社,1999:105-130
40刘兴龙.锤击消除焊接应力的数值模拟.济南:山东大学材料学院,2005
41刘倩.大口径直缝焊管扩径消应工艺模拟.[天津大学硕士论文].2006
42陈翠欣.X80高强管线钢的焊接性及其模拟仿真.[天津大学硕士论文].2005
43王长利.焊接温度场和应力场的数值模拟.[沈阳大学硕士论文].2005
44刘习文,王国荣,肖心远.基于ANSYS的熔化极弧焊温度场三维数值模拟.金属铸锻焊技术,2008,37(5):85-89
45 Lancaster J F. The Physics of Welding.New York, NY: Pergamon Press, 1984:267-273.
46 Kumar Subodh, Bhaduri S C. Three-Dimensional Finite Element Modeling of Gas Metal-arc Welding. Metallurgical and Materials Transactions, 1994,(25):435-441.
47潘际鉴.自然科学发展战略调研报告.机械制造科学(热加工).北京:机械工业出版社,1995:26-46
48 L.M.HABIB, U.KLEEN, F.OTREMNA. Numerical Simulation of Weld Residual Stresses and Countermeasures in Austenitic Steel Piping. International Conference on Nuclear Engineering Proceedings, ICONE, 1997:25-29
49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
50 N.NASSTROM, L.WILANDER, L.KARLSSON. Combined 3-D and SHELL modeling of welding.Proc of IUTAM Symposium on the Mechanical Effects of Welding. Lulea, Sweden:Springer, Germany, 1992:197-206
51 Y.UEDA, J.WANG, H.MURAKAWA. Three Dimensional Numerical Simulation of Variousthermal-mechanical Processes by FEM(ReportⅠ). Trans JWRI, 1992,21(2):111-117
52 Carpenter N. Locking and Shear Scaling Factors in Bending Elements. Computers and Structures, 1986,22(1):39-52
53 Y.UEDA, J.WANG, H.MURAKAWA. Three Dimensional Numerical Simulation of Various Thermal-mechanical Processes by FEM(ReportⅢ).Trans JWRI, 1993,22(1):127-134
54 Y.UEDA, J.WANG, H.MURAKAWA. Three Dimensional Numerical Simulation of Various Thermal-mechanical Processes by FEM(ReportⅣ).Trans JWRI, 1992,22(2):289-294
55蔡志鹏,赵海燕,吴甦,等.串热源模型及其在焊接数值模拟中的应用.机械工程学报,2001,37(3):25-28
56董晓强,段宏.基于ANSYS的异种材料堆焊温度场动态模拟.沈阳工业大学学报,2008,30(5):551-553
57李萌盛,严红丹,王洋.不同约束下试板中心堆焊焊接变形的模拟.热加工工艺,2009,38(3):119-123
58 D.DENG, L.YU, H.SEFIZAWA. Numerical Simulation of Residual Stress and Deformation Considering Phase Transformation Effect. Transaction of JWRI, 2003, 32(2):325-333
59傅荣柏,起重机钢结构制造工艺.北京:中国铁道出版社,1991
60李巧颜.参数化的船体平板分段焊接变形预测.[哈尔滨工程大学硕士学位论文].2007
2张芸.桥式起重机常见机械故障分析及预防措施.科技信息,2009,(7):486
3须雷.现代起重机的特征和发展动态.起重运输机械,1997,(10):3-7
4王国强.现代设计技术.北京:化学工业出版社,2006
5 Q.J.PENG, C.S.YU. Enhanced Integrated Manufacturing Systems in an Immersive Virtual Environment. Journal of Engineering Manufacture. 2007,221(83):447-487
6田锡唐.焊接结构.北京:机械工业出版社,1982
7增援兴一.焊接结构分析.北京:机械工业出版社,1983:158-161
8贾安东.焊接结构与生产.第2版.北京:机械工业出版社,2007
9潘际蜜.展望21世纪焊接科研.中国机械工程,2000,11(2):23-25
10张朝晖.ANSYS8.0结构分析及实例解析.北京:机械工业出版社,2005
11樊杰,赵轶,徐清浩.有限元法的一般思想.科技情报开发与经济.2008,18(3):157-158
12吕召会.有限元法在工程设计中的应用.电子机械工程.2005,21(4):59-60
13谢江波,刘亚青,张鹏飞.有限元方法概述.设计与研究.2007,(5):29-30
14徐小波.塑性成型的刚塑性有限元方法概述.中国水运(理论版),2006,4(4):102-103
15郝伟,张洪,郝永福.有限元方法在接触问题中的应用.机械管理开发,2005,(2):49
16 W.C.A.THACKER, Brief Review of Methods Used for Generating Irregular Computational Grids. International Journal for Numerical Method in Engineering, 1980,(15):1335-1341
17 H.O.LEK. Finite Element Mesh Generation Methods. A Review and Classification. Computer Aided Design, 1988,20(1):27-38
18王焕定,焦兆平.有限单元法基础.北京:高等教育出版社,2002
19傅永华.有限元分析基础.武汉:武汉大学出版社,2003
20叶绍松,阮祥发,赵燕.有限元法在结构分析中的应用.机械研究与应用.2005,18(4):8-9
21赵经文,王宏钰.结构有限元分析.北京:科学出版社,2001
22 ANSYS, Inc. ANSYS Tutorials for Release5.4.Forth Edition. SAS, IP Inc. 1997
23 ANSYS, Inc. ANSYS Analysis Guides First Edition. SAS, IP Inc. 1997
24 ANSYS, Inc. ANSYS Commands Reference. Ninth Edition. SAS, IP Inc. 1997
25 ANSYS, Inc. ANSYS Elements Reference. Ninth Edition. SAS, IP Inc. 1997
26停永华,陈定方.起重机结构件加筋对结构强度与刚度的影响.起重运输机械,1996(5):30-31
27王小慧,程文明,杨春松,等.起重机金属结构有限元分析的模型处理技术.起重运输机械, 2006(9):33-34
28谭建国.使用ANSYS 6.0进行有限元分析.北京:北京大学出版社,2002
29 E.J.HAUG, J.S.ARORA. Applied Optimal Design. Awiley Interseienee Publieation, 1979
30 R.J. AGUILAR. Systems Analysis and Design. Preniice-HallIne.Englewood, Cliffs N.J. 1973
31 P.E.GILL, W.MURRAY. Wright M H. Practical Optimization, Academic Press Inc London: LTD, 1981
32祝磊,马赢.ANSYS7.0入门与提高.北京:清华大学出版社,2004:3
33 ANSYS, Inc. ANSYS Advanced Optimazation Nson Analysis System, Inc. 1994
34起重机设计规范修订组,起重机设计规范(GB3811-2008).北京:中国标准出版社,2008
35刘兴龙,曲仕尧,邹增大等.基于ANSYS的焊接过程有限元模拟.电焊机.2007(7):41-43
36黄开文.国外高钢级管线钢的研究与使用情况.焊管,2003,26(3):1-10
37 Y.SHAH. Computational Trends in Engineering Simulation. In MCAE’97 International Seminar, Beijing, 1997:8-10
38汪建华,戚新海,钟小敏.三维瞬态焊接温度场的有限元模拟.上海交通大学学报,1996,30(3):121-125
39陈丙森.计算机辅助焊接技术北京机械工业出版社,1999:105-130
40刘兴龙.锤击消除焊接应力的数值模拟.济南:山东大学材料学院,2005
41刘倩.大口径直缝焊管扩径消应工艺模拟.[天津大学硕士论文].2006
42陈翠欣.X80高强管线钢的焊接性及其模拟仿真.[天津大学硕士论文].2005
43王长利.焊接温度场和应力场的数值模拟.[沈阳大学硕士论文].2005
44刘习文,王国荣,肖心远.基于ANSYS的熔化极弧焊温度场三维数值模拟.金属铸锻焊技术,2008,37(5):85-89
45 Lancaster J F. The Physics of Welding.New York, NY: Pergamon Press, 1984:267-273.
46 Kumar Subodh, Bhaduri S C. Three-Dimensional Finite Element Modeling of Gas Metal-arc Welding. Metallurgical and Materials Transactions, 1994,(25):435-441.
47潘际鉴.自然科学发展战略调研报告.机械制造科学(热加工).北京:机械工业出版社,1995:26-46
48 L.M.HABIB, U.KLEEN, F.OTREMNA. Numerical Simulation of Weld Residual Stresses and Countermeasures in Austenitic Steel Piping. International Conference on Nuclear Engineering Proceedings, ICONE, 1997:25-29
49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
50 N.NASSTROM, L.WILANDER, L.KARLSSON. Combined 3-D and SHELL modeling of welding.Proc of IUTAM Symposium on the Mechanical Effects of Welding. Lulea, Sweden:Springer, Germany, 1992:197-206
51 Y.UEDA, J.WANG, H.MURAKAWA. Three Dimensional Numerical Simulation of Variousthermal-mechanical Processes by FEM(ReportⅠ). Trans JWRI, 1992,21(2):111-117
52 Carpenter N. Locking and Shear Scaling Factors in Bending Elements. Computers and Structures, 1986,22(1):39-52
53 Y.UEDA, J.WANG, H.MURAKAWA. Three Dimensional Numerical Simulation of Various Thermal-mechanical Processes by FEM(ReportⅢ).Trans JWRI, 1993,22(1):127-134
54 Y.UEDA, J.WANG, H.MURAKAWA. Three Dimensional Numerical Simulation of Various Thermal-mechanical Processes by FEM(ReportⅣ).Trans JWRI, 1992,22(2):289-294
55蔡志鹏,赵海燕,吴甦,等.串热源模型及其在焊接数值模拟中的应用.机械工程学报,2001,37(3):25-28
56董晓强,段宏.基于ANSYS的异种材料堆焊温度场动态模拟.沈阳工业大学学报,2008,30(5):551-553
57李萌盛,严红丹,王洋.不同约束下试板中心堆焊焊接变形的模拟.热加工工艺,2009,38(3):119-123
58 D.DENG, L.YU, H.SEFIZAWA. Numerical Simulation of Residual Stress and Deformation Considering Phase Transformation Effect. Transaction of JWRI, 2003, 32(2):325-333
59傅荣柏,起重机钢结构制造工艺.北京:中国铁道出版社,1991
60李巧颜.参数化的船体平板分段焊接变形预测.[哈尔滨工程大学硕士学位论文].2007