摘要
近年来,随着数值方法和计算机技术的发展,采用有限元模拟研究焊接残余应力的方法得以发展,目前对于大型复杂结构焊接残余应力的研究比较热门。工字钢-端板组焊结构是建筑工程中最常见的节点构造形式之一,在对这种结构进行焊接过程三维有限元分析时,不但实体模型构建和有限元网格划分非常困难,而且计算时间冗长,使这类结构的有限元模拟研究受到了很大程度的限制,到目前为止,有关该类结构焊接残余应力三维有限元分析的研究尚未见报道。
本课题以中厚板工字钢-端板组焊结构为研究对象,采用ANSYS软件的参数化设计语言编制有限元计算程序,选择基于生死单元技术的移动体热源模型,对模拟计算过程中所用的参考温度、焊接电流、电弧电压、焊接速度、焊缝熔融断面尺寸等部分参数进行试验测定,建立了可行的焊接温度场和应力场的数值模拟方法,对组焊结构整体模型的焊接温度场和焊接残余应力场进行了三维有限元模拟,对模拟计算结果进行了分析。本研究利用红外测量仪对观察点的焊接热循环实测,对焊缝断面熔合线观察实测,并采用盲孔法对焊接残余应力进行测量,以验证模拟结果的可靠性。温度场模拟结果与实测结果吻合良好,焊接残余应力模拟结果与测量结果趋势基本一致,表明本文三维数值模拟分析方法可行,数据可靠,为大型复杂结构整体构件焊接温度场及应力场数值模拟研究与实际应用提供了技术支持和理论依据。焊接温度场和焊接残余应力的模拟分析结论,可以为制定焊接工艺、调控焊接残余应力、优化焊接顺序等提供参考。
针对大型复杂焊接结构整体模拟困难的问题,本课题提出了三种解决大型复杂钢结构焊接残余应力模拟问题的简化计算新方法,即整体结构分解算法、对称性结构简化计算方法、远距离焊缝整体结构简化计算方法,并对分解模型的尺寸及边界约束条件对焊接残余应力模拟结果的影响进行了研究,为大型复杂钢结构焊接残余应力定量计算和分析提供了新颖的方法,并可大幅度提高计算效率。
本文还研究了焊接顺序对整体结构焊接残余应力的影响。在本文焊接工艺和约束条件下,焊接顺序可以改变组焊结构焊接残余应力的分布,但对残余应力峰值的影响较小,可为合理制定焊接工艺提供理论依据。
本文的总体研究成果,可以为数值模拟技术在大型复杂结构焊接过程模拟研究、结构及工艺设计、工程施工中的应用提供基础性参考,具有重要的理论意义和工程实际应用价值。
In recent years, with the development of numerical calculation methods and computer technology, numerical simulation for welding residual stress has been developed. But the study focusing on welding residual stress for large and complex structure is limited, due to the complexity of the welding process and restriction of computing capacity. The welding assembly of I-beam and end-plate is a widely used node form in steel structures. But for the three-dimensional (3D) finite element analysis on welding process for such complex and large welded structure, it is very difficult to build3D physical model and divide finite element mesh. In addition, the calculation is time-consuming. These reasons limited the numerical simulation study for this type of welded structure. Research work on3D finite element analysis of welding residual stress for I-beam and end-plate welding assembly has not been reported until now.
In this paper, welding assembly of I-beam and end-plate with medium plate was taken as the research model, moving body heat source model was adopted based on the birth-death technique, welding temperature field and residual stress were calculated via parametric design language of ANSYS software, and the simulation results were analyzed. Parameters used in the simulation process such as reference temperature, welding current, arc voltage, welding speed and size of weld section were obtained by experimental method. Infrared thermometers were employed to measure temperatures of test points on the weld seams, the fusion line of the weld cross-section was observed and measured to verify the validity of simulation results. The hole-drilling method was adopted to determine residual stress for verification purpose. Simulation and experimental results of temperature field are in good agreement, simulation and measurement results of welding residual stress distribution trend are roughly the same, prove that in this paper the3D finite element analysis method is feasible and the data are reliable. The results of this study provide support for practical application and simulation research on welding temperature field and stress field of large and complex structure.
According to the difficulty for numerical simulation on full-scale model of large and complex welded structure, three kinds of simplified algorithm were proposed, namely split method, simplified method for symmetrical structure and simplified method for structure with long-distance welds. The influence of the size and boundary constraint conditions of the split model on the simulation results of welding residual stress were studied. These simplified methods provide a novel approach for quantitative calculation and analysis of welding residual stress for large and complex steel structure, and can significantly improve computational efficiency.
This paper also studied the effect of welding sequence on welding residual stress. The results show that the change of the welding sequence has a significant influence on the distribution pattern of the stress, but has little influence on the peak value of welding residual stress. This conclusion provides a theoretical basis for the reasonable welding process design.
In summary, the study of this paper provides basic reference for research of finite elememt simulation applied in welding process design, structure optimization of large and complex welded structure. It has important theoretical significance and practical engineering value.
引文
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