CN111611680A - Manufacturing method of internal pressure steel oval end socket designed based on failure mode - Google Patents
Manufacturing method of internal pressure steel oval end socket designed based on failure mode Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 24
- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 22
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- 238000013461 design Methods 0.000 claims abstract description 47
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- 239000004576 sand Substances 0.000 claims description 2
- 230000000694 effects Effects 0.000 abstract description 4
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- 238000005482 strain hardening Methods 0.000 description 5
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- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
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Abstract
The invention relates to the field of pressure vessels, and aims to provide a method for manufacturing an internal pressure steel oval end socket designed based on a failure mode. The method comprises the following steps: determining the calculated pressure, and primarily selecting the size and the material of the seal head; determining the calculated thickness required for preventing the plastic collapse failure of the elliptical seal head; adding the negative deviation of the thickness of the steel plate and the corrosion allowance to the calculated thickness of the elliptical seal head, and rounding upwards to the thickness of the standard specification of the steel plate to be used as the nominal thickness of the elliptical seal head; and processing by using the nominal thickness of the seal head and the size and material of the initially selected seal head according to the specification of the manufacturing standard of the elliptical seal head by adopting a conventional manufacturing method to obtain an elliptical seal head product. The invention comprehensively considers two failure modes of buckling and plastic collapse of the internal pressure elliptical seal head, and overcomes the defect that the design calculation formula for preventing buckling failure of the elliptical seal head is lacked in the existing standard. The invention is based on the elastoplasticity theory, considers the spheroidization effect of the elliptical seal head, can reduce the wall thickness of the seal head, saves materials and has better economic benefit.
Description
Technical Field
The invention relates to the field of pressure vessels, in particular to a method for manufacturing an internal pressure steel oval end socket designed based on a failure mode.
Background
The elliptical seal head is widely applied to various industries such as energy, chemical industry, food, pharmacy and the like, is an indispensable important basic part of pressure vessels such as various storage tanks, heat exchangers, reaction kettles, separators, containment vessels of nuclear power plants and the like, and has a huge application amount of vessels subjected to internal pressure load. The mechanical behavior of the steel oval end socket under the action of the internal pressure load is complex, small elastic deformation occurs firstly, and then the plastic deformation stage is carried out after yielding. Due to the strain hardening effect of the material and the structural characteristics of the elliptical seal head, the deformation of the elliptical seal head tends to be hemispherical along with the rise of pressure, spheroidization occurs, and finally the seal head is plastically collapsed to lose effectiveness and completely loses the bearing capacity. In addition, because the elliptical seal head transition area is subjected to hoop compressive stress, when the diameter-thickness ratio or the diameter-height ratio of the seal head is larger than a certain value, buckling failure occurs in the seal head transition area, and after the seal head is spheroidized, plastic collapse failure finally occurs. Therefore, the plastic collapse failure and the buckling failure are two important failure modes which need to be considered when the internal pressure elliptical seal head is designed.
Regarding the design method of the internal pressure elliptical seal head, the national standard GB/T150 adopts an elastic design rule based on maximum stress, and JB4732 adopts an ideal elastic-plastic design concept based on ultimate load so as to prevent the elliptical seal head from plastic collapse and failure. However, neither of the two standard design methods for preventing plastic collapse failure of the elliptical head takes into account the effects of strain hardening and head spheroidization of the material. For buckling failure, the two standards only indicate that the end socket exceeding a certain diameter-thickness ratio needs stability checking, but no specific method guidance and specification is made, and the design and manufacture of the ultra-large and ultra-thin oval end socket are not facilitated. Although American specifications ASME PBVC VIII-1 and VIII-2 and European Union standard EN13445-3 all give a design method of an internal pressure elliptical seal head based on a failure mode, the design method for preventing plastic collapse failure is also based on an elastic theory or an ideal elastic-plastic theory, and the influence of material strain hardening and seal head spheroidization is not considered. Research shows that the design method for preventing the internal pressure elliptical seal head from plastic collapse failure based on the elasticity theory or the ideal elastoplasticity theory gives a too conservative design result because the influence of material strain hardening and seal head spheroidization is not taken into account, and material waste is caused. If the strain hardening and the end socket spheroidization of the material can be considered, the bearing capacity of the elliptical end socket is fully utilized, the wall thickness of the elliptical end socket is reduced, the cost is saved, and the product competitiveness is improved.
Disclosure of Invention
The invention aims to solve the technical problem of overcoming the defects in the prior art and provides a manufacturing method of an internal pressure steel oval end socket designed based on a failure mode.
In order to solve the technical problem, the solution of the invention is as follows:
the manufacturing method of the internal pressure steel oval end socket based on the failure mode design comprises the following steps:
(1) determining a calculated pressure p based on the design conditions of the pressure vesselcPreliminarily selecting the inner diameter D of the end socketiAspect ratio of
And the material used by the seal head, and the standard yield strength S of the material used by the seal head at the design temperature is determined according to the standard of the pressure containeryAnd allowable stress Sm；
(2) Determining the calculated thickness required for preventing plastic collapse failure of the elliptical seal heads：
In the formula:sthe calculated thickness required for preventing the plastic collapse failure of the elliptical seal head is in mm; p is a radical ofcFor calculation of pressure, in MPa; diThe inner diameter of the elliptic end socket is in unit mm; smThe allowable stress of the material used for the end socket is in unit MPa, α is an elliptical end socket calculation coefficient, and the value range is 0.27-0.45;
(3) if D isi/sLess than or equal to 200, calculating the thickness obtained in the step (2)sThe numerical value of (A) is used as the calculated thickness of the elliptical seal head, unitmm；
If D isi/sIf the thickness is more than 200, determining the calculated thickness required for preventing the buckling failure of the elliptical seal head according to the following formulab：
In the formula: diThe inner diameter of the elliptic end socket is in unit mm; p is a radical ofcFor calculation of pressure, in MPa; syThe standard yield strength of the material used for the end socket at the design temperature is in MPa;
the diameter-height ratio of the end socket is β, the reduction factor is β for the elliptical end socket manufactured by a split mode is 0.77, the reduction factor for the elliptical end socket manufactured by a stamping or spinning mode is β, the ratio of the diameter-height ratio of the end socket to the height of the elliptical end socket manufactured by a stamping or spinning mode is 1.0:
then, the calculated thickness required to prevent plastic collapse failure is takensAnd calculated thickness required to prevent buckling failurebThe larger value of the two is used as the calculated thickness of the elliptical seal head in unit mm;
adding the negative deviation of the thickness of the steel plate and the corrosion allowance to the calculated thickness of the elliptical seal head, and rounding upwards to the thickness of the standard specification of the steel plate to be used as the nominal thickness of the elliptical seal head;
(4) and (3) processing the elliptic end socket product by using the nominal thickness of the end socket obtained in the step (3) and the size and the material of the end socket selected in the step (1) according to the specification of the manufacturing standard of the elliptic end socket by using a conventional manufacturing method.
In the invention, in the step (2), for the elliptical seal head without the splicing welding joint, the value range of the calculation coefficient alpha of the elliptical seal head is 0.27-0.30.
In the invention, the diameter-thickness ratio of the elliptical seal head
It should satisfy:
in the invention, the diameter-height ratio of the elliptical seal head
It should satisfy:
in the invention, the material of the elliptical seal head is carbon steel, low alloy steel or high alloy steel which meets the manufacturing standard of the pressure container.
In the present invention, the conventional manufacturing method in the step (4) includes a stamping, spinning or split machining method.
With respect to the calculated pressure pcDescription of (1):
the pressure vessel design process generally begins with pressure vessel design conditions that include vessel design criteria, operating pressure, operating temperature, media composition and characteristics, and other information. The present invention begins with the identification of pressure vessel design conditions. For pressure vessel design, there is a working pressure, a design pressure, and a calculated pressure. The operating pressure is the highest pressure that can be reached at the top of the vessel under normal operating conditions. Designing pressure: the set maximum pressure at the top of the vessel is not lower than the operating pressure. And (3) calculating pressure: the pressure used to determine the thickness of the container element, i.e. the pressure in the calculation formula, includes additional loads such as hydrostatic pressure. Assuming that the working pressure determined according to the process conditions is 10MPa, the design pressure may be set to 1.1 times the working pressure, i.e., the design pressure is 11 MPa. Without additional load, the calculated pressure may be 11MPa, the same as the design pressure; if the hydrostatic pressure of the liquid column is 0.2MPa, the calculated pressure is 11.2 MPa.
Adding the negative deviation of the thickness of the steel plate and the corrosion allowance to the calculated thickness of the elliptical seal head, and rounding upwards to the thickness of the standard specification of the steel plate to be used as the nominal thickness of the elliptical seal head; this process is well within the skill of those skilled in the art and will not be described further herein.
Description of the inventive principles:
in the manufacturing method, the adopted calculation formula of the thickness of the elliptical seal head is obtained based on a prediction formula of buckling pressure and plastic collapse pressure of the elliptical seal head, verified by the test result of the elliptical seal head in industrial scale and considering enough safety allowance. The plastic collapse failure is a failure mode which is inevitable when the internal pressure elliptical seal head is used, and the calculated thickness required for preventing the plastic collapse failure must be determined when elliptical seal heads with all dimensions are designed. However, when the diameter-thickness ratio of the elliptical seal head is Di/sWhen the thickness of the end socket is more than 200 ℃, buckling failure can occur, at the moment, the calculated thicknesses required by two failure modes of preventing plastic collapse failure and buckling failure are required to be determined simultaneously, and the larger value of the calculated thicknesses corresponding to the two failure modes is taken as the calculated thickness of the elliptical end socket, so that the plastic collapse failure and the buckling failure are prevented.
Compared with the prior art, the invention has the beneficial effects that:
1. the method comprehensively considers two failure modes of buckling and plastic collapse of the internal pressure elliptical seal head, provides a seal head wall thickness calculation method for the two failure modes respectively, and overcomes the defect that a design calculation formula for preventing buckling failure of the elliptical seal head is lacked in the existing standard.
2. The wall thickness calculation method for preventing the plastic collapse failure of the elliptical seal head is based on an elastic-plastic theory, considers the spheroidizing effect of the elliptical seal head, can reduce the wall thickness of the seal head, saves materials and has better economic benefit.
Drawings
Fig. 1 is a schematic cross-sectional view of an elliptical head.
Detailed Description
Specific example 1:
the implementation of the invention is described with reference to fig. 1 and specific example 1, and compared with the existing specification standard:
the design conditions of the elliptical head are shown in table 1:
TABLE 1 design conditions for elliptical heads
| Design pressure | 5MPa | Design temperature | 40℃ |
| Working medium | Nitrogen gas | Inner diameter of seal head | 600mm |
| Material | Q245R | Negative deviation C of steel plate thickness1 | 0.3mm |
| Corrosion allowance C2 | 0mm | Coefficient of weld joint | 1.0 |
(1) According to the design condition of the container, because the working medium is gas, the static pressure of the liquid column does not need to be considered, and the calculated pressure is consistent with the design pressure, namely pc5 MPa. Preliminarily selecting the inner diameter D of the end socketi600mm and diameter to height ratio
And a material Q245R for the end socket. The yield strength S of a material Q245R used for the end socket at the design temperature of 40 ℃ is determined according to the pressure vessel standard GB/T150.2y239MPa and allowable stress Sm＝148MPa。
(2) Determining the calculation thickness required for preventing the plastic collapse failure of the elliptical seal head according to the following formula, wherein the seal head with the diameter of 600mm can be manufactured by stamping a whole plate, a splicing welding joint is not required, and the calculation coefficient alpha of the elliptical seal head can be 0.27;
(3) due to Di/s109 is less than or equal to 200, and the calculated thickness of the elliptic end socket is equal tos＝5.5mm。
Adding the calculated thickness of the elliptical seal head (5.5 mm) to the negative deviation (C) of the thickness of the steel plate10.3mm) and corrosion margin (C)20mm) and rounding up to the thickness of the steel plate standard specification, which is the nominal thickness of the elliptical head, namely the nominal thickness of the elliptical head is taken to be 6 mm.
(4) And (3) processing by using the nominal thickness of the end socket obtained in the step (3) and the size and the material of the end socket selected in the step (1) according to the specification of the manufacturing standard of the elliptical end socket by adopting a stamping manufacturing method to obtain an elliptical end socket product.
The comparison between the calculated thickness of the elliptical seal head obtained by the method of the invention and the value obtained by the existing standard design method is shown in table 2.
TABLE 2 comparison of calculated thicknesses of elliptical heads for the method of the present invention and the current standard design method
| Method of producing a composite material | GB/T 150 | JB 4732 | ASME VIII.1 | ASME VIII.2 | EN13445 | Method of the invention |
| Calculated thickness/mm | 10.2 | 11.1 | 10.2 | 9.2 | 14.5 | 5.5 |
As can be seen from Table 2, the calculated thickness of the elliptical head obtained by the method can be reduced by more than 40% compared with the existing standard design method, so that the elliptical head product designed and manufactured by the method has thinner wall thickness, the cost is saved, and the competitiveness of the product is improved.
The elliptical head product is manufactured by the design calculation data obtained by the method, and the plastic collapse test is carried out on the head product, and the plastic collapse pressure of the head is measured to be 16.9MPa, which is 3.4 times of the design pressure, so that the elliptical head designed and manufactured by the method has enough safety margin.
Specific example 2:
the implementation process of the invention is described with reference to the attached figure 1 and the specific example 2:
the design conditions for the elliptical head are shown in table 3:
TABLE 3 design conditions for oval head
| Design pressure | 0.25MPa | Design temperature | 40℃ |
| Working medium | Nitrogen gas | Inner diameter of seal head | 1800mm |
| Material | S31603 | Negative deviation C of steel plate thickness1 | 0.3mm |
| Corrosion allowance C2 | 0mm | Coefficient of weld joint | 1.0 |
(1) According to the design condition, because the working medium is gas, the static pressure of the liquid column does not need to be considered, and the calculated pressure is consistent with the design pressure, namely pc0.25 MPa. Preliminarily selecting the inner diameter D of the end socketi1800mm and aspect ratio
And a material S31603 for the seal head, and determining the yield strength S of the material S31603 for the seal head at the design temperature of 40 ℃ according to the pressure vessel standard GB/T150.2y172MPa and allowable stress Sm＝120MPa。
(2) Determining the calculated thickness for preventing the plastic collapse failure of the elliptical seal head according to the following formulas1800mm diameter stainless steel sealThe head can be manufactured by stamping the whole plate containing the splicing welding seam, and the calculation coefficient α of the elliptical end socket is 0.40;
(3) due to Di/sWhen the thickness is 1200 to 200, the calculated thickness required for preventing the buckling failure of the elliptical seal head is determined according to the following formulabThe oval end socket is manufactured by stamping, and β is 1.0.
Due to the fact thatb＞sThe calculated thickness of the elliptical seal head is equal tob＝2.4mm。
Adding the calculated thickness of the elliptical seal head (2.4 mm) to the negative deviation (C) of the thickness of the steel plate10.3mm) and corrosion margin (C)20mm) and rounding up to the thickness of the steel plate standard specification, which is the nominal thickness of the elliptical head, namely the nominal thickness of the elliptical head is taken to be 3 mm.
(4) And (3) processing by using the nominal thickness of the end socket obtained in the step (3) and the size and the material of the end socket selected in the step (1) according to the specification of the manufacturing standard of the elliptical end socket by adopting a stamping manufacturing method to obtain an elliptical end socket product.
The design calculation data obtained by the method of the invention is used for manufacturing an elliptical end socket product, and the bending test is carried out on the end socket product, so that the bending pressure of the end socket is measured to be 1.43MPa which is 5.7 times of the design pressure, and the elliptical end socket designed and manufactured by the method of the invention still has enough safety margin.
Claims (6)
1. A manufacturing method of an internal pressure steel oval end socket designed based on a failure mode is characterized by comprising the following steps:
(1) determining a calculated pressure p based on the design conditions of the pressure vesselcPreliminarily selecting the inner diameter D of the end socketiAspect ratio of
And the material used by the seal head, and the standard yield strength S of the material used by the seal head at the design temperature is determined according to the standard of the pressure containeryAnd allowable stress Sm；
(2) Determining the calculated thickness required for preventing plastic collapse failure of the elliptical seal heads：
In the formula:sthe calculated thickness required for preventing the plastic collapse failure of the elliptical seal head is in mm; p is a radical ofcFor calculation of pressure, in MPa; diThe inner diameter of the elliptic end socket is in unit mm; smThe allowable stress of the material used for the end socket is in unit MPa, α is an elliptical end socket calculation coefficient, and the value range is 0.27-0.45;
(3) if D isi/sLess than or equal to 200, calculating the thickness obtained in the step (2)sThe numerical value of (A) is used as the calculated thickness of the elliptical seal head, and the unit is mm;
if D isi/sIf the thickness is more than 200, determining the calculated thickness required for preventing the buckling failure of the elliptical seal head according to the following formulab：
In the formula: diThe inner diameter of the elliptic end socket is in unit mm; p is a radical ofcFor calculation of pressure, in MPa; syThe standard yield strength of the material used for the end socket at the design temperature is in MPa;
the diameter-height ratio of the end socket is β, the reduction factor is β for the elliptical end socket manufactured by a split mode is 0.77, and the reduction factor is β for the elliptical end socket manufactured by a stamping or spinning mode is 1.0;
then, taking the need to prevent plastic collapse failureCalculated thickness ofsAnd calculated thickness required to prevent buckling failurebThe larger value of the two is used as the calculated thickness of the elliptical seal head in unit mm;
adding the negative deviation of the thickness of the steel plate and the corrosion allowance to the calculated thickness of the elliptical seal head, and rounding upwards to the thickness of the standard specification of the steel plate to be used as the nominal thickness of the elliptical seal head;
(4) and (3) processing the elliptic end socket product by using the nominal thickness of the end socket obtained in the step (3) and the size and the material of the end socket selected in the step (1) according to the specification of the manufacturing standard of the elliptic end socket by using a conventional manufacturing method.
2. The method according to claim 1, wherein in the step (2), for the elliptical head without the spliced welding joint, the value of the calculation coefficient alpha of the elliptical head ranges from 0.27 to 0.30.
3. The method of claim 1, wherein the elliptical head has a ratio of diameter to thickness
It should satisfy:
4. the method of claim 1, wherein the elliptical head has a diameter to height ratio
It should satisfy:
5. the method of claim 1, wherein the material of the elliptical head is carbon steel, low alloy steel or high alloy steel that meets the manufacturing standards for pressure vessels.
6. The method of claim 1, wherein the conventional manufacturing method in step (4) comprises a stamping, spinning or split machining method.
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