CN110530541B - Calculation method capable of accurately simulating postweld heat treatment temperature field of large pressure container - Google Patents
Calculation method capable of accurately simulating postweld heat treatment temperature field of large pressure container Download PDFInfo
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- 238000010438 heat treatment Methods 0.000 title claims abstract description 171
- 238000004364 calculation method Methods 0.000 title claims abstract description 10
- 238000004088 simulation Methods 0.000 claims abstract description 87
- 238000009826 distribution Methods 0.000 claims abstract description 22
- 238000000034 method Methods 0.000 claims abstract description 20
- 238000002474 experimental method Methods 0.000 claims abstract description 19
- 238000003466 welding Methods 0.000 claims description 50
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- 229910000831 Steel Inorganic materials 0.000 claims description 11
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- 229920000742 Cotton Polymers 0.000 claims description 8
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- 230000000630 rising effect Effects 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000005192 partition Methods 0.000 description 3
- 238000007669 thermal treatment Methods 0.000 description 3
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- G01K—MEASURING TEMPERATURE; MEASURING QUANTITY OF HEAT; THERMALLY-SENSITIVE ELEMENTS NOT OTHERWISE PROVIDED FOR
- G01K7/00—Measuring temperature based on the use of electric or magnetic elements directly sensitive to heat ; Power supply therefor, e.g. using thermoelectric elements
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Abstract
The invention relates to the technical field of heat treatment, and provides a calculation method capable of accurately simulating a postweld heat treatment temperature field of a large pressure container, which comprises the following steps: (1) determining a heat treatment process; (2) simulating a heat treatment experiment to obtain a heat treatment temperature field; (3) dividing the heat treatment area to obtain an equivalent amplitude temperature curve required by a simulated temperature field; (4) and (4) performing finite element equivalent amplitude heat source numerical simulation. The simulation piece heat treatment experiment adopted by the invention can well represent the temperature field distribution of an actual heat treatment structure, and the accuracy and the authenticity of numerical simulation local heat treatment temperature fields are improved; the finite element equivalent amplitude heat source numerical simulation is carried out through the strong convection coefficient and the equivalent amplitude temperature curve, the simulation temperature curve can be well controlled to strictly follow the actual temperature, and the accurate simulation of the local heat treatment temperature field is realized.
Description
Technical Field
The invention relates to the technical field of heat treatment, in particular to a calculation method capable of accurately simulating a postweld heat treatment temperature field of a large pressure container.
Background
In recent years, China is moving from a large manufacturing country to a strong manufacturing country, the manufacturing capacity of large-scale equipment in a great field is continuously improved, foreign monopoly is broken, and autonomous localization is increasingly realized. Among them, more and more large-scale pressure vessels realize ultra-large, high-parameter and long-period operation, and are widely applied to the fields of petrochemical industry, energy storage, nuclear power and the like, and the manufacturing and integrity of the vessels have great significance.
Postweld heat treatment is an important process link for manufacturing large pressure vessels. The whole heat treatment cannot be adopted due to the limitation of the volume of the heat treatment furnace, and only the local heat treatment can be adopted. Numerical simulation provides a feasible method for researching local heat treatment. Whether the temperature field simulation is accurate or not is directly related to the accuracy of the welding residual stress and the heat treatment stress and deformation simulation. However, the traditional electric heating heat treatment simulation method considers convection, radiation and conduction, has a complex process and is difficult to accurately simulate; the traditional constant heat flow density model can only be used for simply controlling the whole temperature change of the heat treatment.
Disclosure of Invention
The invention aims to provide a calculation method capable of accurately simulating a postweld heat treatment temperature field of a large-sized pressure container, which is used for applying heat source loads in a subarea mode based on the temperature distribution characteristics of all areas of a soaking zone (SB), a heating zone (HB) and a heat insulation zone (HCB), and controlling a simulated temperature curve to strictly follow the actual temperature through a strong convection coefficient and an equivalent amplitude temperature curve so as to realize accurate simulation of a local heat treatment temperature field.
The invention adopts the following technical scheme:
a calculation method capable of accurately simulating a postweld heat treatment temperature field of a large pressure vessel comprises the following steps:
step 1, determining a heat treatment process;
further, the step 1 of determining the heat treatment process is to determine key process parameters of the heat treatment according to standard and numerical simulation: temperature rising and falling rate control, heat preservation time, heat preservation temperature, and the width of a heating area and a heat preservation area.
Further, the standard is GB150 or ASME B & PV specification volume iii.
Step 2, simulating a heat treatment experiment of the workpiece to obtain a heat treatment temperature field
Classifying the simulated welding joints according to the simulated actual heat treatment structure, extracting simulation pieces which are the same as the welding joints, carrying out a local heat treatment experiment on the simulation pieces, wherein the adopted heat treatment process is the same as the field actual heat treatment structure, simulating the temperature field distribution of different areas of the actual heat treatment structure by adjusting the spatial position of the welding seams of the simulation pieces, and taking the heat treatment temperature field obtained by the simulation pieces as the input of the heat treatment temperature field of the numerical simulation of the actual heat treatment structure;
drawing a temperature distribution curve of the temperature in the heat preservation stage along the direction vertical to the welding line to obtain a temperature field of the simulation piece in the direction vertical to the welding line;
further, in step 2, the obtaining of the temperature field of the simulation piece in the direction perpendicular to the weld joint is specifically: and extracting one group of temperature data in the heat treatment and heat preservation stage every 15 minutes, extracting six groups of temperature data, calculating an average value, and drawing a temperature distribution curve of the temperature along the direction vertical to the welding line so as to obtain a temperature field of the simulation piece in the direction vertical to the welding line.
Further, in the step 2, the simulation part is formed by splicing and welding steel plates which are the same in material and thickness as the actual product to be subjected to heat treatment.
Further, in the step 2, when the simulation piece is subjected to the local heat treatment experiment, the temperature thermocouple is arranged in the direction perpendicular to the welding seam at the center of the simulation piece.
Further specifically, the arrangement of the temperature thermocouple takes the edge of the welding seam as a starting point, one position is arranged at every 50mm in the heat insulation cotton covering area, and one position is arranged at every 100mm outside the heat insulation cotton until reaching the edge of the test panel.
Furthermore, the temperature control thermocouple is welded on a 20mm multiplied by 20mm thin steel sheet, and the thin steel sheet is positioned at the highest temperature position of the heating sheet and fixed on the heating sheet and further fixed on the tool.
Further, the temperature thermocouple is connected to a paperless recorder through a compensation lead, the real-time temperature of each temperature measuring point of the heat treatment is recorded, and the paperless recorder is set to record temperature data every 10 s; the temperature control thermocouple is connected to a heat treatment temperature controller through a compensation lead to control the heat treatment temperature.
In step 2 of the above technical scheme, the most critical input condition for performing local thermal treatment numerical simulation on the large container is a thermal treatment temperature field, and in order to obtain more accurate temperature data, the most critical input condition is obtained through a simulation heat treatment experiment. The method specifically comprises the following steps: and classifying the simulated welding joints according to the simulated actual model, extracting simulation pieces which are the same as the welding joints, and splicing and welding the simulation pieces by steel plates which are the same as the products in material and thickness. And carrying out a local heat treatment experiment on the simulation piece, wherein the heating, heat preservation and temperature control modes are the same as those of the field. And simulating the temperature field distribution of different areas of the actual heat treatment structure by adjusting the spatial position of the welding line of the simulation piece. The temperature field obtained by the simulation piece is used as the input of the temperature field of the numerical simulation of the actual heat treatment structure.
Wherein, the temperature thermocouple is arranged in the direction vertical to the welding seam at the center of the simulation piece. With the edge of the welding seam as a starting point, arranging thermocouples in the heat-insulating cotton covering area every 50 mm; and arranging thermocouples outside the heat preservation cotton every 100mm until the edge of the test plate. And connecting the temperature thermocouple to a paperless recorder through a compensation lead, recording the real-time temperature of each temperature measuring point during heat treatment, and recording temperature data once every 10s by the paperless recorder. The temperature control thermocouple is welded on a 20mm multiplied by 20mm thin steel sheet which is positioned at the highest temperature of the heating sheet and is fixed on the heating sheet fixing tool. The temperature control thermocouple is connected to a heat treatment temperature controller through a compensation lead to control the heat treatment temperature.
Temperature thermocouples at different positions obtain heat treatment curves at different positions; and extracting one group of temperature data every 15 minutes in the heat treatment and heat preservation stage, extracting six groups of temperature data, calculating an average value, and drawing a temperature distribution curve of the temperature along the direction vertical to the welding seam so as to obtain the temperature field of the simulation piece in the direction vertical to the welding seam.
Step 3, the heat treatment area is divided to obtain an equivalent amplitude temperature curve required by the simulated temperature field
Based on the temperature distribution characteristics of all regions of the soaking zone, the heating zone and the heat insulation zone, subdividing the region of the vertical welding line according to data obtained by experiments on the basis, wherein the distance between the regions is integral multiple of the distance between the thermocouples;
determining temperature peak values of different areas in the heat preservation stage according to a temperature field of the simulation piece in the direction vertical to the welding line obtained in the heat treatment heat preservation stage, wherein the temperature peak values are specifically average values of temperatures of adjacent thermocouples in the areas;
determining equivalent amplitude temperature curves of different areas according to heat treatment curves recorded by different temperature thermocouples, and inputting the equivalent amplitude temperature curves as a heat source for simulating heat treatment;
in step 3 of the above technical scheme, the heat treatment region is divided to obtain heat treatment curves of different regions, i.e. equivalent amplitude temperature curves required by the simulated temperature field.
The basis of the partition is as follows: based on the temperature distribution characteristics of each region of the soaking zone (SB), the heating zone (HB) and the heat insulation zone (HCB), the region of the vertical welding line is subdivided according to data obtained by experiments, and the distance between the regions is integral multiple of the distance between the thermocouples.
The basis for determining the equivalent amplitude temperature curve is as follows: determining the temperature peak values of different areas in the heat preservation stage according to the temperature gradient in the direction vertical to the welding line in the heat treatment heat preservation stage, wherein the temperature peak values are the average values of the temperatures of the adjacent thermocouples in the areas; and determining equivalent amplitude temperature curves of different areas according to the heat treatment curves recorded by different temperature thermocouples, and inputting the equivalent amplitude temperature curves as a heat source for simulating heat treatment.
Step 4, finite element equivalent amplitude heat source numerical simulation
Establishing a finite element model of an actual heat treatment structure, dividing a welding seam and an adjacent region thereof according to the regions divided in the step 3, setting thermophysical material parameters, setting an equivalent amplitude temperature curve obtained in the step 3, setting a heat treatment analysis step, carrying out collective naming on the regions divided in the step 3, and implementing heat treatment temperature rise and fall simulation by applying a strong convection coefficient and a corresponding equivalent amplitude temperature curve.
Further, in step 4, the grid size of the partition position is equal to or slightly smaller than the spacing of the thermocouples.
In step 4 of the above technical scheme, finite element equivalent amplitude heat source numerical simulation is performed. Establishing a finite element model of an actual heat treatment structure, dividing a welding seam and an adjacent region thereof according to the subareas, setting thermophysical material parameters, setting an equivalent amplitude temperature curve obtained in the step 3, setting a heat treatment analysis step, carrying out collective naming on the regions divided in the step 3, applying different strong convection coefficients and corresponding equivalent amplitude temperature curves as boundary conditions for temperature field simulation, and further realizing that the simulated temperature curve strictly follows the actual temperature. To ensure that the simulation is similar to reality, the grid size of the zone locations is preferably such that the thermocouples are even smaller in pitch and approximately the same size.
The invention has the beneficial effects that:
the adopted simulation piece heat treatment experiment can well represent the temperature field distribution of an actual heat treatment structure, and the accuracy and the authenticity of the numerical simulation local heat treatment temperature field are improved.
The finite element equivalent amplitude heat source numerical simulation is carried out through the strong convection coefficient and the equivalent amplitude temperature curve, the simulation temperature curve can be well controlled to strictly follow the actual temperature, and the accurate simulation of the local heat treatment temperature field is realized.
Drawings
Other objects and results of the present invention will become more apparent and more readily appreciated as the same becomes better understood by reference to the following description taken in conjunction with the accompanying drawings. In the drawings:
FIG. 1 is a schematic flow diagram of the present invention;
FIG. 2 is a view showing a heat source for local heat treatment in embodiment 1;
FIG. 3 is a comparison of the temperature field distribution in the vertical weld direction and the test results of the simulated test piece of embodiment 1 at the heat treatment simulation heat preservation stage;
fig. 4 is a comparison of the distribution of the temperature field in the vertical weld direction and the test results in the heat treatment simulation heat preservation stage of the large-sized insert plate of the ultra-large pressure vessel in the embodiment 2.
Detailed Description
The invention is described in detail below with reference to the accompanying drawings:
referring to fig. 1, a calculation method for accurately simulating a postweld heat treatment temperature field of a large pressure vessel includes the following steps:
step 1. determining the Heat treatment Process
The key process parameters of the thermal treatment were determined according to the corresponding standards (GB150 or ASME B & PV specification volume iii) and numerical simulations: temperature rising and falling rate control, heat preservation time, heat preservation temperature, and the width of a heating area and a heat preservation area.
Step 2, simulating a heat treatment experiment of the workpiece to obtain a heat treatment temperature field
And classifying the simulated welding joints according to the simulated actual heat treatment structure, extracting simulation pieces which are the same as the welding joints, and splicing and welding the simulation pieces by steel plates which are the same as the actual products to be subjected to heat treatment and have the same material and the same thickness.
And carrying out a local heat treatment experiment on the simulation piece, wherein the adopted heat treatment process is the same as the field actual heat treatment structure, the spatial position of the welding seam of the simulation piece is adjusted to simulate the temperature field distribution of different areas of the actual heat treatment structure, and the heat treatment temperature field obtained by the simulation piece is used as the input of the heat treatment temperature field of the numerical simulation of the actual heat treatment structure.
When the simulation piece is used for carrying out a local heat treatment experiment, the temperature thermocouple is arranged in the direction perpendicular to the weld joint at the center of the simulation piece; specifically, the arrangement of the temperature thermocouples takes the edge of a welding seam as a starting point, one position is arranged at every 50mm in the coverage area of the heat insulation cotton, and one position is arranged at every 100mm outside the heat insulation cotton till the edge of the test panel.
The temperature control thermocouple is welded on a 20mm multiplied by 20mm thin steel sheet, and the thin steel sheet is positioned at the highest temperature of the heating sheet and is fixed on the heating sheet and further fixed on the tool.
Connecting a temperature thermocouple to a paperless recorder through a compensation lead, recording the real-time temperature of each temperature measuring point of heat treatment, and recording temperature data once every 10s by the paperless recorder; the temperature control thermocouple is connected to a heat treatment temperature controller through a compensation lead to control the heat treatment temperature.
Temperature thermocouples at different positions obtain heat treatment curves at different positions; and extracting one group of temperature data every 15 minutes in the heat treatment and heat preservation stage, extracting six groups of temperature data, calculating an average value, and drawing a temperature distribution curve of the temperature along the direction vertical to the welding seam so as to obtain the temperature field of the simulation piece in the direction vertical to the welding seam.
Step 3, the heat treatment area is divided to obtain an equivalent amplitude temperature curve required by the simulated temperature field
And (4) dividing the heat treatment area to obtain heat treatment curves of different areas, namely equivalent amplitude temperature curves required by the simulated temperature field. The basis of the partition is as follows: based on the temperature distribution characteristics of each region of the soaking zone (SB), the heating zone (HB) and the heat insulation zone (HCB), the region of the vertical welding line is subdivided according to data obtained by experiments, and the distance between the regions is integral multiple of the distance between the thermocouples.
The basis for determining the equivalent amplitude temperature curve is as follows: determining the temperature peak values of different areas in the heat preservation stage according to the temperature gradient in the direction vertical to the welding line in the heat treatment heat preservation stage, wherein the temperature peak values are the average values of the temperatures of the adjacent thermocouples in the areas; and determining equivalent amplitude temperature curves of different areas according to the heat treatment curves recorded by different temperature thermocouples, and inputting the equivalent amplitude temperature curves as a heat source for simulating heat treatment.
Step 4, finite element equivalent amplitude heat source numerical simulation
Establishing a finite element model of an actual heat treatment structure, dividing a welding seam and an adjacent region thereof according to the regions divided in the step 3, setting thermophysical material parameters, setting an equivalent amplitude temperature curve obtained in the step 3, setting a heat treatment analysis step, carrying out collective naming on the regions divided in the step 3, applying different strong convection coefficients and corresponding equivalent amplitude temperature curves as boundary conditions for temperature field simulation, and further realizing that the simulated temperature curve strictly follows the actual temperature. To ensure that the simulation is similar to reality, the grid size of the zone locations is such that the thermocouples are even smaller in pitch and approximately the same size.
Example 1
Heat treatment simulation test pieces: the material Q345 is 3000 × 2000 × 100(50) (mm).
And setting a heat treatment temperature curve according to the standard requirement to finish the whole postweld heat treatment process.
The temperature thermocouple is connected to a paperless recorder through a compensating lead, the real-time temperature of each temperature measuring point of the heat treatment is recorded, and the paperless recorder is set to record temperature data every 10 s. The temperature control thermocouple is connected to a heat treatment temperature controller through a compensation lead to control the heat treatment temperature. Modeling a heat treatment simulation test piece, and setting thermophysical material parameters, thermal boundary conditions (convection and radiation) and a heat treatment curve. The local heat treatment heat source is shown in figure 2; the comparison of the temperature field distribution in the direction of the vertical weld joint in the heat treatment simulation heat preservation stage and the test result is shown in figure 3.
The simulation results show that: by using the heat treatment simulation method, the obtained temperature field perpendicular to the direction of the welding seam in the heat treatment heat preservation stage is well consistent with the actual temperature field.
Example 2
Inputting the temperature field of the simulated test piece obtained in the embodiment 1 as the temperature field for local heat treatment of the butt weld of the large-scale insert plate and the cylinder of a certain super-large pressure vessel, establishing a finite element model of an actual heat treatment structure, dividing the butt weld and the adjacent region thereof according to the subareas, setting thermophysical material parameters, setting the equivalent amplitude temperature curve obtained in the step 3, setting a heat treatment analysis step, carrying out collective naming on the regions divided in the step 3, and realizing heat treatment temperature rise and fall simulation by applying a strong convection coefficient and the corresponding equivalent amplitude temperature curve. The local heat treatment adopts a heat source shown in FIG. 2; the local heat treatment simulation of the large-scale insert plate of the super-large pressure vessel is shown in figure 4, and the distribution of the temperature field in the direction of the vertical welding line in the heat preservation stage and the test result are compared.
The simulation results show that: by using the heat treatment simulation method, the obtained temperature field perpendicular to the direction of the welding seam in the heat treatment heat preservation stage is well consistent with the actual temperature field.
The simulation piece heat treatment experiment adopted by the invention can well represent the temperature field distribution of an actual heat treatment structure, and the accuracy and the authenticity of numerical simulation local heat treatment temperature fields are improved; the finite element equivalent amplitude heat source numerical simulation is carried out through the strong convection coefficient and the equivalent amplitude temperature curve, the simulation temperature curve can be well controlled to strictly follow the actual temperature, and the accurate simulation of the local heat treatment temperature field is realized.
It is to be understood that the above description is not intended to limit the present invention, and the present invention is not limited to the above examples, and those skilled in the art may make modifications, alterations, additions or substitutions within the spirit and scope of the present invention.
Claims (3)
1. A calculation method capable of accurately simulating a postweld heat treatment temperature field of a large pressure vessel is characterized by comprising the following steps:
step 1. determining the Heat treatment Process
The heat treatment process is characterized in that key process parameters of heat treatment are determined according to GB150 or ASMEB & PV specification volume III by combining numerical simulation: controlling the temperature rising and falling rate, the heat preservation time, the heat preservation temperature, and the widths of the heating area and the heat preservation area;
step 2, simulating a heat treatment experiment of the workpiece to obtain a heat treatment temperature field
Classifying the simulated welding joints according to the simulated actual heat treatment structure, extracting simulation pieces which are the same as the welding joints, splicing and welding the simulation pieces by steel plates which are the same in material and thickness as the actual product to be subjected to heat treatment, carrying out a local heat treatment experiment on the simulation pieces, carrying out the same heat treatment process as the field actual heat treatment structure, simulating the distribution of temperature fields in different areas of the actual heat treatment structure by adjusting the spatial position of the welding seams of the simulation pieces, and taking the heat treatment temperature field obtained by the simulation pieces as the input of the heat treatment temperature field numerically simulated by the actual heat treatment structure;
when the simulation piece is used for carrying out a local heat treatment experiment, the temperature thermocouple is arranged in the direction perpendicular to the weld joint at the center of the simulation piece; the arrangement of the temperature thermocouples takes the edge of a welding seam as a starting point, one position is arranged at every 50mm in the coverage area of the heat insulation cotton, and one position is arranged at every 100mm outside the heat insulation cotton till the edge of the test plate;
the temperature control thermocouple is welded on a 20mm multiplied by 20mm thin steel sheet, and the thin steel sheet is positioned at the highest temperature of the heating sheet and is fixed on the heating sheet and further fixed on the tool;
connecting a temperature thermocouple to a paperless recorder through a compensation lead, recording the real-time temperature of each temperature measuring point of heat treatment, and recording temperature data once every 10s by the paperless recorder; the temperature control thermocouple is connected to a heat treatment temperature controller through a compensation lead to control the heat treatment temperature;
drawing a temperature distribution curve of the temperature in the heat preservation stage along the direction vertical to the welding line to obtain a temperature field of the simulation piece in the direction vertical to the welding line;
step 3, the heat treatment area is divided to obtain an equivalent amplitude temperature curve required by the simulated temperature field
Based on the temperature distribution characteristics of all regions of the soaking zone, the heating zone and the heat insulation zone, subdividing the region of the vertical welding line according to data obtained by experiments on the basis, wherein the distance between the regions is integral multiple of the distance between the thermocouples;
determining temperature peak values of different areas in the heat preservation stage according to a temperature field of the simulation piece in the direction vertical to the welding line obtained in the heat treatment heat preservation stage, wherein the temperature peak values are specifically average values of temperatures of adjacent thermocouples in the areas;
determining equivalent amplitude temperature curves of different areas according to heat treatment curves recorded by different temperature thermocouples, and inputting the equivalent amplitude temperature curves as a heat source for simulating heat treatment;
step 4, finite element equivalent amplitude heat source numerical simulation
Establishing a finite element model of an actual heat treatment structure, dividing a welding seam and an adjacent region thereof according to the regions divided in the step 3, setting thermophysical material parameters, setting an equivalent amplitude temperature curve obtained in the step 3, setting a heat treatment analysis step, carrying out collective naming on the regions divided in the step 3, and implementing heat treatment temperature rise and fall simulation by applying a strong convection coefficient and a corresponding equivalent amplitude temperature curve.
2. The calculation method for the post-weld heat treatment temperature field capable of accurately simulating the large pressure vessel according to claim 1, wherein in the step 2, the temperature field of the simulation piece in the direction perpendicular to the weld joint is obtained specifically as follows: and extracting one group of temperature data in the heat treatment and heat preservation stage every 15 minutes, extracting six groups of temperature data, calculating an average value, and drawing a temperature distribution curve of the temperature along the direction vertical to the welding line so as to obtain a temperature field of the simulation piece in the direction vertical to the welding line.
3. The calculation method for the post-weld heat treatment temperature field capable of accurately simulating the large-sized pressure vessel as claimed in claim 1, wherein in the step 4, the grid size of the subarea position is equal to or slightly smaller than the distance between the thermocouples.
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