CN110399694B - Method for analyzing and eliminating hidden defects of welded pipe - Google Patents
Method for analyzing and eliminating hidden defects of welded pipe Download PDFInfo
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Abstract
The invention discloses a numerical calculation method for analyzing and eliminating hidden defects of welded pipes. The method comprises the following steps: setting geometric parameters in the integral models of high-frequency welding and medium-frequency heat treatment of the welded pipe as variables, and assigning values to the set variables; establishing a welding and heat treatment integral model by using Hypermesh to perform grid optimization; importing the generated model into ANSYS, and setting high-frequency welding, medium-frequency heat treatment boundary conditions, initial conditions, thermal physical environment and electromagnetic physical environment files; performing intermediate-frequency heat treatment on the electromagnetic field and the temperature field; introducing SYSWELD into the geometric model and the grid, setting boundary conditions and physical environments according to the characteristics of the tube blank material, and introducing SYSWELD into temperature field data extracted from ANSYS as initial conditions; calculating the residual stress distribution of the welded pipe after air cooling to room temperature; adjusting the distance between the first internal coil and the second internal coil in the heat treatment according to the residual stress calculation result; and repeating the steps to calculate the residual stress distribution of the welded pipe after the distance is changed. The method is favorable for eliminating the hidden defect of the welded pipe.
Description
Technical Field
The invention relates to the field of welding heat treatment, in particular to a method for analyzing and eliminating hidden defects of a welded pipe.
Background
When the high-frequency straight seam welding of the welded pipe is carried out, the induction coil loads high-frequency current, the high-frequency current energy is concentrated in a V-shaped corner area at the edge of a welding seam by utilizing the skin effect and the proximity effect, and the plate edge is rapidly and instantly heated to the welding temperature from the room temperature. High-frequency resistance welding, electromagnetic heating energy is concentrated, although the heating surface is small, the thermal gradient is large; the local intermediate frequency heat treatment of the welding seam is carried out on the basis of high-frequency welding, and the welding waste heat in the online production is utilized. The superposition effect of high and medium frequency twice heating and the temperature value matching degree of the welding seam area of the welded pipe are closely related to the generation of welding quality defects. The targeting of the medium-frequency heat treatment is a direct reason that a heating blind area and a heating excessive area become high-incidence areas of welding quality defects. The welding quality defects are different from the defects of welding cracks, slag inclusion, air holes, welding seam appearance and the like detected by conventional flaw detection, and comprise material characteristic defects which are hidden in welding seams and heat affected zones and are discretely distributed at different positions, such as the problems of low toughness, high hardness, large residual stress, poor stability of comprehensive mechanical properties and the like shown in certain areas, and the defects are called hidden defects because of large potential safety hazards to the service burial of welded pipes under severe conditions. The method is a technical problem in order to accurately obtain the position where the hidden defects are influenced by the welded pipe and eliminate the hidden defects.
Disclosure of Invention
The invention aims to provide a method for analyzing and eliminating hidden defects of a welded pipe, which is used for accurately acquiring the positions of the welded pipe influencing the hidden defects and eliminating the hidden defects, thereby improving the welding quality of the high-frequency welded pipe.
In order to achieve the purpose, the method adopts the following technical scheme: a method for analyzing and eliminating hidden defects of welded pipes is characterized by comprising the following steps:
setting a welded pipe high-frequency welding and intermediate-frequency heat treatment integral model, which comprises a pipe blank with an opening angle, electrodes and array magnetic rods adopted in a high-frequency welding stage, a main coil and an auxiliary coil which are arranged outside the intermediate-frequency heat treatment, and an internal coil I and an internal coil II which are arranged inside the intermediate-frequency heat treatment; the distance between the first internal coil and the second internal coil is d, and the set variable is assigned;
establishing a welding and heat treatment integral model by using Hypermesh, and carrying out grid division on the model, wherein the grid optimization is carried out on the welding seam center and a heat affected zone;
importing the geometric model and the grid generated by Hypermesh into ANSYS, and setting boundary conditions and initial conditions of high-frequency welding and medium-frequency heat treatment; setting a high-frequency resistance welding thermal physical environment file and an electromagnetic physical environment file, and solving a high-frequency resistance welding electromagnetic field and a temperature field; setting a medium-frequency heat treatment thermal physical environment file and an electromagnetic physical environment file, realizing continuous heating of high-frequency welding and heat treatment by equivalent tube blank moving process through a node load moving method, and solving an electromagnetic field and a temperature field after medium-frequency heat treatment; extracting the temperature of each node on the welded pipe after heat treatment in ANSYS, and storing a data file;
introducing a Hypermesh generated geometric model and a grid into SYSWELD, setting boundary conditions, initial conditions and physical environments according to the characteristics of a tube blank material, and introducing temperature field data extracted from ANSYS into SYSWELD as the initial conditions; calling a physical environment file to obtain the residual stress distribution of the welded pipe after air cooling to room temperature; extracting an equivalent residual stress cloud picture of a welding seam area of the section of the welded pipe; fitting a residual stress concentration distribution area of a welding seam area of the welded pipe and extracting a maximum stress value;
and calculating the distance between the first internal coil and the second internal coil after heat treatment according to the residual stress simulation calculation result, taking the distance as a new internal coil distance d, and repeating the steps to calculate the residual stress distribution of the welded pipe after the distance is changed, so that overlarge residual stress in the welded area of the welded pipe after heat treatment is eliminated, and hidden defects are eliminated.
The further technical scheme is that in the grid optimization process, the weld joint center and the heat affected zone within 10mm of the weld joint center are divided by adopting hexahedral grids, and the sizes of the to-be-welded zones of the weld joint and the tube blank along the axial direction are the same.
The technical scheme is that the boundary conditions and initial conditions of the high-frequency welding and the medium-frequency heat treatment comprise that the temperature load moving step length is equal to integral multiple of the length of a grid dividing unit so as to ensure the smooth movement of a temperature field, and the normal component of the magnetic force line at the boundary of an air area is set to be zero; the high-frequency welding initial condition is that the tube blank is heated from room temperature; and the temperature distribution after air cooling for t seconds after high-frequency welding heating is used as an initial temperature field of medium-frequency heat treatment.
The further technical scheme is that when only hidden defect generation analysis of the welded pipe is carried out, the internal coil I and the internal coil II are not activated and do not participate in intermediate frequency heat treatment heating; and when the hidden defect analysis of the welded pipe is eliminated, activating the first internal coil and the second internal coil to participate in intermediate frequency heat treatment heating.
Compared with the prior art, the invention has the following advantages:
1. the integral electromagnetic-thermal-motion coupling model of high-frequency welding and medium-frequency heat treatment is established, the numerical calculation precision is improved, the result is more accurate and reliable, the problem of the hidden defect which is difficult to detect in the welded pipe is conveniently and accurately analyzed, and a foundation is laid for further improving the quality of the welded pipe.
2. When in heat treatment, apart from the external induction coil of the welded pipe, the double internal coils with adjustable spacing are arranged, the spacing between the internal coils can be adjusted according to the numerical calculation result of the residual stress, so that the overlarge residual stress generated after the heat treatment is eliminated, and the occurrence of hidden defects is reduced.
3. The simulation process is based on various numerical calculation software, the simulation process is automatic, calculation can be performed aiming at the welding and heat treatment induction heating processes of the welded pipe under different process conditions, operation is convenient, and cost is low.
Drawings
FIG. 1 is a flow chart of a numerical calculation method of the present invention;
FIG. 2 is a schematic view of an induction heating coil upon which the present invention is based during heat treatment;
FIG. 3 is a schematic view of a geometric model;
FIG. 4 is a schematic diagram of an optimized meshing;
FIG. 5 is a cloud view of the simulated results of the temperature field after heat treatment without the inner coil;
FIG. 6 is a cloud of equivalent residual stresses in the weld zone of the cross-section of the welded tube after heat treatment without the inner coil;
FIG. 7 is a cloud of equivalent residual stresses in the weld zone of a welded tube section after heat treatment with an internal coil.
Reference numerals: 1-secondary coil, 2-magnetizer, 3-main coil, 4-welded tube, 5-internal coil I, 6-internal coil II, 7-welding seam, 8-high-frequency welding electrode and 9-array magnetic bar.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1, the numerical calculation method for analyzing and eliminating the hidden defect of the welded pipe of the present invention specifically includes:
TABLE 1 basic parameters
step 6, as shown in FIG. 5, extracting the temperature of each node on the welded pipe after heat treatment in ANSYS, and storing a data file;
step 10, extracting an equivalent residual stress cloud chart of a welding seam area of the section of the welded pipe, and calculating a distance d between a first internal coil and a second internal coil of the heat treatment according to a residual stress simulation distribution result;
and 11, changing the distance d between the inner coils, repeating the steps 9-11 to calculate the residual stress distribution of the welded pipe after the distance is changed until the residual stress exceeding the use limit value of the welded pipe after the heat treatment of the welding area of the welded pipe is eliminated, and eliminating the hidden defect.
As shown in fig. 2 to 3, the heat treatment apparatus on which the numerical calculation method is based includes: the device comprises an auxiliary coil 1, a magnetizer 2, a main coil 3, an internal coil I5 and an internal coil II 6, wherein the auxiliary coil 1, the magnetizer 2 and the main coil 3 are arranged right above the outer surface of a welded pipe 4 and are 4.5mm away from a welding seam of the welded pipe 4, the internal coil I5 and the internal coil II 6 are arranged right below the inner surface of the welded pipe 4 and are 4.5mm away from the welding seam of the welded pipe 4, and when only hidden defects of the welded pipe 4 are analyzed, the internal coil I5 and the internal coil II 6 are not activated and do not participate in intermediate frequency heat treatment heating; and when the hidden defect analysis of the welded pipe 4 is eliminated, activating the first internal coil 5 and the second internal coil 6 to participate in intermediate frequency heat treatment heating.
Claims (1)
1. A method for analyzing and eliminating hidden defects of welded pipes is characterized by comprising the following steps:
setting a welded pipe high-frequency welding and intermediate-frequency heat treatment integral model, which comprises a pipe blank with an opening angle, electrodes and array magnetic rods adopted in a high-frequency welding stage, a main coil and an auxiliary coil which are arranged outside the intermediate-frequency heat treatment, and an internal coil I and an internal coil II which are arranged inside the intermediate-frequency heat treatment; wherein the first internal coil is spaced from the second internal coil by a distance ofdAssigning values to the set variables;
establishing a welding and heat treatment integral model by using Hypermesh, and carrying out grid division on the model, wherein the grid optimization is carried out on the welding seam center and a heat affected zone; in the grid optimization process, the weld joint center and the heat affected zone within 10mm from the weld joint center are divided by adopting hexahedral grids, and the sizes of the weld joint and the area to be welded of the tube blank along the axial direction are the same;
importing the geometric model and the grid generated by Hypermesh into ANSYS, and setting boundary conditions and initial conditions of high-frequency welding and medium-frequency heat treatment; setting a high-frequency resistance welding thermal physical environment file and an electromagnetic physical environment file, and solving a high-frequency resistance welding electromagnetic field and a temperature field; setting a medium-frequency heat treatment thermal physical environment file and an electromagnetic physical environment file, realizing continuous heating of high-frequency welding and heat treatment by equivalent tube blank moving process through a node load moving method, and solving an electromagnetic field and a temperature field after medium-frequency heat treatment; extracting the temperature of each node on the welded pipe after heat treatment in ANSYS, and storing a data file; the boundary conditions and initial conditions of the high-frequency welding and the intermediate-frequency heat treatment comprise that the temperature load moving step length is equal to integral multiple of the length of a grid dividing unit so as to ensure the smooth movement of a temperature field, and the normal component of a magnetic line of force at the boundary of an air area is set to be zero; the high-frequency welding initial condition is that the tube blank is heated from room temperature; the temperature distribution after air cooling for t seconds after high-frequency welding heating is used as an initial temperature field of medium-frequency heat treatment; when only hidden defect generation analysis of the welded pipe is carried out, the first internal coil and the second internal coil are not activated and do not participate in intermediate frequency heat treatment heating; activating the first internal coil and the second internal coil to participate in intermediate frequency heat treatment heating when analysis for eliminating hidden defects of the welded pipe is carried out;
introducing a Hypermesh generated geometric model and a grid into SYSWELD, setting boundary conditions, initial conditions and physical environments according to the characteristics of a tube blank material, and introducing temperature field data extracted from ANSYS into SYSWELD as the initial conditions; calling a physical environment file to obtain the residual stress distribution of the welded pipe after air cooling to room temperature; extracting an equivalent residual stress cloud picture of a welding seam area of the section of the welded pipe; fitting a residual stress concentration distribution area of a welding seam area of the welded pipe and extracting a maximum stress value;
calculating the distance between the first internal coil and the second internal coil according to the residual stress simulation calculation result, and using the distance as a new internal coil distancedAnd repeating the steps to calculate the residual stress distribution of the welded pipe after the distance is changed, so that the overlarge residual stress after the heat treatment of the welding area of the welded pipe is eliminated, and the hidden defect is eliminated.
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Effective date of registration: 20211222 Address after: No. 6-5, Changhui Road, wind power park, Huishan Economic Development Zone, Wuxi, Jiangsu 214000 Patentee after: WUXI YUANLONG METAL PRODUCTS CO.,LTD. Address before: 066004 No. 438 west section of Hebei Avenue, seaport District, Hebei, Qinhuangdao Patentee before: Yanshan University |
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Denomination of invention: A method for analyzing and eliminating hidden defects in welded pipes Granted publication date: 20210702 Pledgee: Bank of China Limited by Share Ltd. Wuxi Huishan branch Pledgor: WUXI YUANLONG METAL PRODUCTS CO.,LTD. Registration number: Y2024980006420 |