CN112149330B - Welding residual stress prediction and welding process optimization method for wind power tower oil seal platform - Google Patents
Welding residual stress prediction and welding process optimization method for wind power tower oil seal platform Download PDFInfo
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Abstract
The invention discloses a method for predicting welding residual stress of a wind power tower oil seal platform and a method for optimizing a welding process, which comprises the following steps: obtaining structural parameters of a wind power tower, welding material parameters, welding modes and heat source parameters; establishing a three-dimensional model of the wind power tower with the welding seam according to the structural parameters of the wind power tower; determining a heat source model according to a welding mode; performing finite element mesh division on the three-dimensional model of the wind power tower; based on the three-dimensional model, the heat source parameters and the welding material parameters of the wind power tower after finite element grid division, welding simulation is carried out, finite element analysis is carried out on a temperature field and a stress field in the welding process, a residual stress prediction result of the wind power tower after welding is obtained, and a reference basis is provided for optimizing welding process parameters, so that a welding process can be adjusted and optimized, an excellent welding seam is obtained, and the service life of the wind power tower is prolonged.
Description
Technical Field
The invention relates to the technical field of welding of wind power tower oil seal platforms, in particular to a method for predicting welding residual stress of a wind power tower oil seal platform and a welding process optimization method.
Background
Wind power generation has been widely used in recent years because of its advantages of cleanliness, environmental protection, reproducibility, inexhaustibility, short construction period, and low running and maintenance costs. Wind towers are one of the key components of wind power plants. The safety performance of wind power towers directly affects the efficiency, service life and performance of wind power plants. The wind power generation tower may be damaged, cracked or deformed due to wind load, gravity load, long-term severe working environment and other factors, and finally the wind power generation tower is unstable or cracked, resulting in huge economic loss. The welding and corrosion prevention processes are the two most main processes for manufacturing the tower, and are the processes most prone to quality problems. Therefore, the welding process of the accessories is optimized, and excellent welding seams are obtained as far as possible.
Disclosure of Invention
The invention aims to provide a method for predicting welding residual stress of a wind power tower oil seal platform and a method for optimizing a welding process. The technical scheme adopted by the invention is as follows.
On one hand, the invention provides a method for predicting welding residual stress of a wind power tower oil seal platform, which comprises the following steps:
obtaining structural parameters of a wind power tower, welding material parameters, welding modes and heat source parameters;
establishing a three-dimensional model of the wind power tower with the welding seam according to the structural parameters of the wind power tower;
determining a heat source model according to a welding mode;
performing finite element mesh division on the three-dimensional model of the wind power tower;
based on the three-dimensional model, the heat source parameters and the welding material parameters of the wind power tower after finite element grid division, welding simulation is carried out, finite element analysis is carried out on a temperature field and a stress field in the welding process, and a residual stress prediction result of the wind power tower after welding is obtained.
Optionally, the heat source parameters include: welding current, voltage, welding speed, and weld line energy; welding material parameters include heat transfer coefficient, specific heat capacity, density, enthalpy, and other parameters that may be considered.
Alternatively, if the welding mode is CO 2 The gas shielded arc welding is performed, the heat source model is a double-ellipsoid heat source model, and the heat source distribution of the first half part/the second half part is as follows:
wherein: q represents heat flux in J/m -2 ·s -1 ；Q 1,2 I.e. Q 1 、Q 2 The energy density of the front half part and the rear half part of the double-ellipsoid heat source is expressed as J/m 3 ；a 1,2 I.e. a 1 、a 2 ，a 1 B, c and a 2 B, c are the axial length parameters of the front half part and the rear half part of the corresponding double-ellipsoid heat source respectively; (x, y, z) represents coordinates with respect to the center of the heat source.
Optionally, when finite element mesh division is performed, the mesh density of the part closer to the weld is higher, that is, the part close to the weld adopts a smaller mesh, and the part far away from the weld adopts a larger mesh.
Optionally, the invention utilizes SolidWorks software to build a three-dimensional model of the wind power tower cylinder with the weld; performing finite element Mesh division on the three-dimensional model of the wind power tower by using Visual-Mesh software; and performing welding simulation and finite element analysis by using Visual-gold numerical simulation software to obtain a residual stress prediction result.
Optionally, during welding simulation and finite element analysis, the outer wall of the tower and the oil seal platform are set as base material units, the welding seam is set as filling material unit, and the surface unit at the junction between the welding seam and the air is set as heat exchange surface; and the residual stress prediction results comprise residual stress distribution of a part of the outer wall of the wind power tower vertical to the welding line and residual stress distribution of the outer wall of the wind power tower along the welding line. Residual stress information of the parts can be obtained by taking points on a software interface, and the residual stress influence of the current welding process can be more prominently represented.
In a second aspect, the invention provides a method for optimizing a welding process of an oil seal platform of a wind power tower, which comprises the following steps:
obtaining structural parameters of a wind power tower, and presetting welding material parameters, welding modes and heat source parameters;
according to structural parameters of the wind power tower, a three-dimensional model of the wind power tower is built by utilizing SolidWorks software;
determining a heat source model according to a predetermined welding mode;
performing finite element Mesh division on the three-dimensional model of the wind power tower by using Visual-Mesh software;
based on the three-dimensional model, the heat source parameters and the welding material parameters of the wind power tower after finite element grid division, performing welding simulation by using Visual-gold numerical simulation software, and performing finite element analysis on a temperature field and a stress field in the welding process to obtain a residual stress prediction result of the wind power tower after welding;
judging whether the residual stress prediction result meets the requirement, and if not, adjusting the welding mode and/or the heat source parameters according to the residual stress prediction result;
carrying out residual stress prediction again based on the adjusted welding mode and/or heat source parameters until the residual stress prediction result meets the requirement;
and determining an optimized final welding process according to the welding mode and the heat source parameters meeting the requirements.
Optionally, adjusting the welding mode includes altering the welding sequence.
Advantageous effects
According to the method, the welding process residual stress of the wind power tower oil seal platform is predicted by utilizing welding simulation and finite element analysis, and a reference basis is provided for optimizing welding process parameters, so that the welding process is adjusted and optimized, an excellent welding seam is obtained, and the service life of the wind power tower is prolonged.
Drawings
FIG. 1 is a schematic flow chart of an optimization method of a welding process of a wind power tower oil seal platform;
FIG. 2 is a schematic flow diagram of one embodiment of the welding process optimization method of the present invention;
FIG. 3 is a grid division perspective view of a wind power tower oil seal platform model in the invention;
FIG. 4 is a grid partition of a weld cross-section in accordance with the present invention;
FIG. 5 is a schematic view of the upper bead pick-up point of the present invention;
FIG. 6 is a schematic view of the lower side trace pick-up in the present invention;
FIG. 7 is a schematic view of the thermal cycle curve of the upper bead pick-up point of the present invention;
FIG. 8 is a schematic view of a thermal cycle curve of the lower side trace pick-up point in the present invention;
FIG. 9 is a schematic view of the point of residual stress in the direction perpendicular to the weld line of the outer wall of the tower in the present invention;
FIG. 10 is a schematic view of the point of residual stress on the outer wall of the tower along the weld direction in the present invention;
FIG. 11 is a graph showing residual stress distribution in the direction perpendicular to the weld line on the outer wall of the tower according to the present invention;
FIG. 12 is a graph showing the distribution of residual stresses along the weld direction on the outer wall of the tower according to the present invention.
Detailed Description
Further description is provided below in connection with the drawings and the specific embodiments.
Example 1
The embodiment introduces a method for predicting welding residual stress of a wind power tower oil seal platform, which comprises the following steps:
obtaining structural parameters of a wind power tower, welding material parameters, welding modes and heat source parameters;
establishing a three-dimensional model of the wind power tower with the welding seam according to the structural parameters of the wind power tower;
determining a heat source model according to a welding mode;
performing finite element mesh division on the three-dimensional model of the wind power tower;
based on the three-dimensional model, the heat source parameters and the welding material parameters of the wind power tower after finite element grid division, welding simulation is carried out, finite element analysis is carried out on a temperature field and a stress field in the welding process, and a residual stress prediction result of the wind power tower after welding is obtained.
The heat source parameters include: welding current, voltage, welding speed, and weld line energy; welding material parameters include heat transfer coefficient, specific heat capacity, density, enthalpy, and other parameters that may be considered.
When the heat source model is determined according to the welding mode, the welding mode is assumed to be CO 2 The gas shielded arc welding is performed, the heat source model is a double-ellipsoid heat source model, and the heat source distribution of the first half part/the second half part is as follows:
wherein: q represents heat flux in J/m -2 ·s -1 ；Q 1,2 I.e. Q 1 、Q 2 The energy density of the front half part and the rear half part of the double-ellipsoid heat source is expressed as J/m 3 ；a 1,2 I.e. a 1 、a 2 ，a 1 B, c and a 2 B, c are the axial length parameters of the front half part and the rear half part of the corresponding double-ellipsoid heat source respectively; (x, y, z) represents coordinates with respect to the center of the heat source.
When finite element grid division is performed, the grid density of the part close to the welding line is higher, namely, the part close to the welding line adopts smaller grids, and the part far away from the welding line adopts larger grids.
The invention can utilize SolidWorks software to establish a three-dimensional model of the wind power tower with the weld; performing finite element Mesh division on the three-dimensional model of the wind power tower by using Visual-Mesh software; and performing welding simulation and finite element analysis by using Visual-gold numerical simulation software to obtain a residual stress prediction result.
When welding simulation and finite element analysis are carried out, the outer wall of the tower and the oil seal platform are set as base material body units, the welding seam is set as filling material body units, and the surface unit at the junction between the vicinity of the welding seam and the air is set as a heat exchange surface; and the residual stress prediction results comprise residual stress distribution of a part of the outer wall of the wind power tower vertical to the welding line and residual stress distribution of the outer wall of the wind power tower along the welding line. Residual stress information of the parts can be obtained by taking points on a software interface, and the residual stress influence of the current welding process can be more prominently represented.
Example 2
The embodiment describes a method for optimizing a welding process of an oil seal platform of a wind power tower, and referring to fig. 1, the method comprises the following steps:
obtaining structural parameters of a wind power tower, and presetting welding material parameters, welding modes and heat source parameters;
according to structural parameters of the wind power tower, a three-dimensional model of the wind power tower is built by utilizing SolidWorks software;
determining a heat source model according to a predetermined welding mode;
performing finite element Mesh division on the three-dimensional model of the wind power tower by using Visual-Mesh software;
based on the three-dimensional model, the heat source parameters and the welding material parameters of the wind power tower after finite element grid division, performing welding simulation by using Visual-gold numerical simulation software, and performing finite element analysis on a temperature field and a stress field in the welding process to obtain a residual stress prediction result of the wind power tower after welding;
judging whether the residual stress prediction result meets the requirement, and if not, adjusting the welding mode and/or the heat source parameters according to the residual stress prediction result;
carrying out residual stress prediction again based on the adjusted welding mode and/or heat source parameters until the residual stress prediction result meets the requirement;
and determining an optimized final welding process according to the welding mode and the heat source parameters meeting the requirements.
Referring to fig. 2, the following illustrates the preferred embodiment of the welding process according to the present invention in a test application example.
Step one: and acquiring structural parameters of the wind power tower to be welded, and establishing a three-dimensional model of a welding piece, namely the wind power tower after the oil seal platform is welded by utilizing SolidWorks according to the actual size of the wind power tower. As shown in fig. 3, wherein the weld was 45 beveled and left a blunt edge of 6 mm.
Step two: finite element meshing is performed by Visual-Mesh software.
When the grids are divided, finer grids are adopted at the positions close to the welding seams, and larger grids are adopted at the positions far away from the welding seams; the model meshing and the weld cross-section meshing are shown in figures 3 and 4, respectively.
Step three: a welding method is predetermined, a heat source model is selected according to the welding method, and heat source parameters are preset.
If the welding method adopts CO2 gas shielded arc welding, the heat source model can be obtained as a double-ellipsoid heat source model according to the shape simulation of a molten pool, wherein the upper half part is a 1/4 ellipsoid, and the lower half part is another 1/4 ellipsoid. The heat sources in the front and back ellipsoids are distributed as follows:
wherein: q represents heat flux in J/m -2 ·s -1 ；Q 1,2 I.e. Q 1 、Q 2 The energy density of the front half part and the rear half part of the double-ellipsoid heat source is expressed as J/m 3 ；a 1,2 I.e. a 1 、a 2 ，a 1 B, c and a 2 B, c are the axial length parameters of the front half part and the rear half part of the corresponding double-ellipsoid heat source respectively; (x, y, z) represents coordinates with respect to the center of the heat source.
The heat source parameters include welding current, voltage, welding speed, and weld line energy.
The predetermined welding process and heat source parameters may include such information as: the welding position adopts flat welding, the metal thickness at the welding joint is 25 mm-100 mm, multi-pass welding is adopted, the welding sequence is that the upper side is welded firstly, the penetration of a welding bead is about 6mm, the temperature between layers is 200 ℃ at the highest, the joint is in a T-shaped joint, and reference is made to figures 4-6; the gas flow is 18-26L/min. The swing parameter is less than or equal to 21mm, the preheating temperature is more than or equal to 110 ℃, the diameter of the nozzle is 20mm, the distance between the nozzle and the workpiece is 15-24 mm, and the post-welding heat treatment is avoided. The welding specific parameters are shown in table 1:
TABLE 1 welding parameters
Step four: and determining various thermal physical performance parameters of the welding material at the welding seam, including heat conduction coefficient, specific heat capacity, density, enthalpy and the like.
Step five: based on the established wind power tower model, the heat source parameters, the welding material parameters and the like, visual-gold numerical simulation software is utilized to conduct finite element analysis of a temperature field and a stress field.
In the process, the outer wall of the tower and the oil seal platform are set as base material body units, the welding line is set as filling material body units, and the surface unit at the junction between the vicinity of the welding line and the air is set as a heat exchange surface. The upper weld bead and the lower weld bead are respectively tapped by the tapping point pair of fig. 5 and 6 through software self-functional analysis, and the thermal cycle curves of the corresponding weld bead tapping points of the application examples are respectively shown in fig. 7 and 8;
the point taking mode of fig. 9 and 10 is adopted to take the points of the part vertical to the welding line and the part along the welding line respectively, and the residual stress distribution curve of the vertical welding line of the outer wall of the tower barrel can be obtained through software analysis and is shown in fig. 11, and the residual stress distribution curve of the part along the welding line on the outer wall of the tower barrel is shown in fig. 12.
At the moment, whether the requirements are met or not can be judged according to the residual stress curve observation, if the residual stress analysis result is not ideal, parameters of a heat source simulated by software can be changed by reducing heat input, or the welding sequence is changed, repeated residual stress prediction is carried out, and finally the optimal heat source parameters and the welding sequence are obtained, namely, the optimization of the welding process is realized.
Through welding process optimization, the optimized welding process is applied to the welding operation of the actual wind power tower oil seal platform to be welded, so that the use safety and the service life of the wind power tower oil seal platform can be ensured.
It will be appreciated by those skilled in the art that embodiments of the present application may be provided as a method, system, or computer program product. Accordingly, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present application may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, and the like) having computer-usable program code embodied therein.
The present application is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the application. It will be understood that each flow and/or block of the flowchart illustrations and/or block diagrams, and combinations of flows and/or blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
The embodiments of the present invention have been described above with reference to the accompanying drawings, but the present invention is not limited to the above-described embodiments, which are merely illustrative and not restrictive, and many forms may be made by those having ordinary skill in the art without departing from the spirit of the present invention and the scope of the claims, which are all within the protection of the present invention.
Claims (6)
1. The optimizing method of the welding process of the wind power tower oil seal platform is characterized by comprising the following steps of:
obtaining structural parameters of a wind power tower, and presetting welding material parameters, welding modes and heat source parameters;
according to structural parameters of the wind power tower, a three-dimensional model of the wind power tower is built by utilizing SolidWorks software;
determining a heat source model according to a predetermined welding mode;
performing finite element Mesh division on the three-dimensional model of the wind power tower by using Visual-Mesh software;
based on the three-dimensional model, the heat source parameters and the welding material parameters of the wind power tower after finite element grid division, performing welding simulation by using Visual-gold numerical simulation software, and performing finite element analysis on a temperature field and a stress field in the welding process to obtain a residual stress prediction result of the wind power tower after welding;
judging whether the residual stress prediction result meets the requirement, and if not, adjusting the welding mode and/or the heat source parameters according to the residual stress prediction result;
carrying out residual stress prediction again based on the adjusted welding mode and/or heat source parameters until the residual stress prediction result meets the requirement;
determining an optimized final welding process according to the welding mode and the heat source parameters meeting the requirements;
when welding simulation and finite element analysis are carried out, the outer wall of the tower and the oil seal platform are set as base material body units, the welding line is set as filling material body units, and the surface unit at the junction between the vicinity of the welding line and the air is set as a heat exchange surface; and the residual stress prediction results comprise residual stress distribution of a part of the outer wall of the wind power tower vertical to the welding line and residual stress distribution of the outer wall of the wind power tower along the welding line.
2. The method of claim 1, wherein adjusting the welding pattern comprises altering a welding sequence.
3. The method of claim 1, wherein the heat source parameters comprise: welding current, voltage, welding speed, and weld line energy; welding material parameters include heat transfer coefficient, specific heat capacity, density, enthalpy, and other parameters that may be considered.
4. The method according to claim 1, wherein if the welding mode is CO 2 The gas shielded arc welding is performed, the heat source model is a double-ellipsoid heat source model, and the heat source distribution of the first half part/the second half part is as follows:
wherein: q represents heat flux; q (Q) 1,2 I.e. Q 1 、Q 2 Respectively representing the energy densities of the front half part and the rear half part of the double-ellipsoid heat source; a, a 1,2 I.e. a 1 、a 2 ，a 1 B, c and a 2 B, c are the axial length parameters of the front half part and the rear half part of the corresponding double-ellipsoid heat source respectively; (x, y, z) represents relative to the heat sourceCoordinates of the center.
5. The method of claim 1, wherein the grid density is greater at locations closer to the weld when the finite element grid division is performed.
6. The method of claim 1, wherein the SolidWorks software is utilized to build a three-dimensional model of the wind power tower with the weld; performing finite element Mesh division on the three-dimensional model of the wind power tower by using Visual-Mesh software; and performing welding simulation and finite element analysis by using Visual-gold numerical simulation software to obtain a residual stress prediction result.
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