CN114528733A - Multipoint distributed heat source welding residual stress regulation and control method for steel bridge deck - Google Patents
Multipoint distributed heat source welding residual stress regulation and control method for steel bridge deck Download PDFInfo
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Abstract
The invention relates to the technical field of welding residual stress heat treatment, in particular to a multipoint distributed heat source welding residual stress regulating and controlling method for a steel bridge deck, which comprises the steps of establishing a three-dimensional thermal elastic plastic finite element model of the steel bridge deck, and simulating a welding temperature field and a stress field according to an analysis result; transmitting the obtained theoretical heating temperature data to an intelligent data processing center; defining a main heating area and an auxiliary heating area according to the change conditions of welding residual stress in different areas away from a welding seam; heating the main heating area and the auxiliary heating area by using oxyacetylene flames, and simultaneously carrying out real-time temperature measurement treatment on the temperature measurement points to obtain real-time temperature data; the intelligent data processing center compares, analyzes and regulates theoretical heating temperature and real-time temperature data; the material temperature is increased to reduce the yield strength, and the residual stress is released, so that the purpose of reducing or homogenizing the residual tensile stress is achieved, and the rigidity, the strength, the stability and the fatigue life of the orthotropic steel bridge deck are improved.
Description
Technical Field
The invention belongs to the technical field of welding residual stress heat treatment, and particularly relates to a multipoint distributed heat source welding residual stress regulating and controlling method for a steel bridge deck, which is suitable for pertinently regulating residual stress at different positions of a welding line of the steel bridge deck.
Background
In recent years, a plurality of large-span steel structure bridges have been built in China, orthotropic steel bridge panels become a reasonable choice of modern bridges with novel structure, economy and environmental protection due to unique advantages, and have been successfully applied to large-span cable-stayed bridges and suspension bridges to form main bearing members of steel box girders, and become an irreplaceable part of the steel box girders. However, in the orthotropic steel bridge deck slab, the longitudinal ribs and the top plate, the transverse partition plate and the top plate, and the longitudinal ribs and the transverse partition plate are rapidly welded and connected, and in the welding process, the base metal in the welding area is rapidly heated and melted by a welding heat source to generate uneven compression plastic deformation, so that residual stress is caused. The existence of welding residual stress affects the safety and durability of the bridge. In order to release, weaken, avoid or eliminate welding residual stress as much as possible, local flame heating is applied to a tensile stress area in a targeted manner according to the spatial distribution state of the residual stress of the steel bridge deck at different positions of each welding seam, the yield strength of a material is reduced along with temperature increase of the material in a heating area, and the residual stress is released, so that the residual tensile stress is reduced or uniform, and the rigidity, strength, stability and fatigue life of the orthotropic steel bridge deck are improved.
At present, various process treatment methods are proposed for improving the fatigue performance of a welded joint: annealing, local heating, TIG welding remelting, laser cladding, overloading, shot blasting, hammering, polishing, etc. Experts and scholars at home and abroad carry out extensive research on local heat treatment technology and adopt modes of local heating sources including flame, electric heating, induction heating and the like. The method for regulating and controlling the welding residual stress of the multipoint distributed heat source adopts a local heating method, and applies the same temperature to a required heating area in a large area and high efficiency by using oxyacetylene flame with a multi-group moving travelling mechanism as a local heating source, so that the temperature has uniformity. Because it forms a movable heating belt, and the temperature can be controlled and regulated, flexibly controlled, etc.
Disclosure of Invention
The invention provides a multi-point distributed heat source welding residual stress regulation and control method for a steel bridge deck slab, which is used for solving the technical problems in the known technology, and the method is combined with a numerical simulation calculation means to analyze the node residual stress spatial distribution state of the steel bridge deck slab, then local oxyacetylene flame heating is applied to a tensile stress area in a targeted manner, the yield strength of a material in a heating area is reduced along with the temperature rise, and the residual stress is released, so that the residual tensile stress is reduced or uniform, the rigidity, the strength, the stability and the fatigue life of an orthotropic steel bridge deck slab are improved, and the safety guarantee is provided for the normal operation of an in-service bridge.
In order to achieve the purpose, the invention adopts the following technical scheme:
a multipoint distributed heat source welding residual stress regulation and control method for a steel bridge deck slab comprises the following steps:
step 1: carrying out surface pretreatment on the steel bridge deck plate, removing residual oxides on the surface of the steel bridge deck plate, removing surface grease and pollutants by using solutions such as acetone and the like, ensuring the flatness of the surface to be adhered, and collecting welding parameters of the steel bridge deck plate;
step 2: establishing a three-dimensional thermal elastic plastic finite element model of the steel bridge deck according to the collected welding parameters of the steel bridge deck, simulating a welding temperature field and a stress field according to an analysis result, and transmitting the obtained theoretical heating temperature data to an intelligent data processing center through a WiFi network;
step 3: preliminarily determining the distribution characteristics of the welding residual stress of the steel bridge deck plate through welding stress field simulation to obtain the change conditions of the welding residual stress in different areas away from a welding seam, and defining different heat source regulation and control areas and marking;
step 4: further refining the heat source regulation and control area, determining a main heating area and an auxiliary heating area by combining numerical simulation, wherein the main heating area is positioned at a position which is 0.6 t-1.2 t close to a welding seam area, t is the thickness of a base material, the auxiliary heating area is positioned at a position which is 2 t-4 t far away from the welding seam area, and the range of the main heating area and the auxiliary heating area is adjusted according to the actual condition;
step 5: heating the main heating area and the auxiliary heating area by adopting oxyacetylene flames with a plurality of groups of moving traveling mechanisms according to set heat source regulation and control parameters, and simultaneously monitoring the temperature of the regulation and control areas in real time by adopting an infrared thermometer to obtain real-time temperature data;
step 6: the intelligent data processing center compares the theoretical heating temperature of step2 with the real-time temperature data of step5, and whether the analysis result is within a specified error range or not;
step 7: after one round of heat source regulation and control is completed, heat preservation treatment is carried out on the main heating area and the auxiliary heating area of the steel bridge deck, and the temperature of the regulation and control area is ensured to be slowly reduced;
step 8: and detecting the residual stress of the regulated key part by using an X-ray diffractometer, evaluating whether the regulation requirement is met, if not, updating the heat source regulation parameters, returning to step3, and starting a new heat source regulation.
As a preferred technical scheme, the temperature field in step2 belongs to standard three-dimensional nonlinear unsteady heat conduction, and the three-dimensional heat conduction control equation in the welding process is as follows:
wherein ρ is the material density (kg × m)-3) (ii) a c is the material specific heat capacity (j/(kg k)); λ is the material thermal conductivity (W/(m × k)); t is the heat transfer time(s); t is a temperature field distribution function;
to solve for internal heat source intensity (W/m) in the region3) (ii) a Where ρ, c, λ are functions of temperature T.
Preferably, in the numerical simulation of the temperature field in step2, the following formula is adopted for calculation, and if the spatial domain Ω is dispersed into finite unit bodies, the temperature T of a certain unit can be approximated by the node temperature TiInterpolation results in that: t ═ NTe；
In the formula, N is an interpolation function, namely a shape function; t iseIs a time-dependent node temperature vector; t is a node temperature vector; k is a heat transfer matrix; c is a heat capacity matrix; p is a temperature load column vector; K. c, P are all temperature-related variables;
as a preferred technical solution, the welding stress field simulation in step3 is calculated by adopting the following formula:
dε＝dεe+dεp+dεT
dσ＝Ddε-CdT
wherein d epsilon is the strain increment caused by temperature change; d εeIs the elastic strain increment; d εTIs the temperature induced strain increase; d is a thermo-elastic-plastic matrix; c is a vector related to temperature; d εeIs the plastic strain increment;
is the equivalent strain increment; d ε0Increase in stress due to temperature change; deIs an elastic matrix.
As a preferable technical scheme, the method for determining the main heating area and the auxiliary heating area in step4 comprises the following steps: setting a region 0.8 t-1.2 t away from the U rib-cover plate joint weld as a first main heating region and a region 2 t-4 t away from the U rib-cover plate joint weld as a first auxiliary heating region; setting a region 0.8 t-1.2 t away from the joint weld of the cover plate-U rib-diaphragm plate as a second main heating region, and setting a region 2 t-4 t away from the joint weld of the cover plate-U rib-diaphragm plate as a second auxiliary heating region; and t is the thickness of the welding seam base metal, and temperature measuring points are arranged at the same time.
As a preferred technical solution, the welding residual stress of the first main heating zone, the first auxiliary heating zone, the second main heating zone and the second auxiliary heating zone in step5 can be calculated by the following formula:
Δε＝ΔεT+ΔεΔV+Δεtrip；
ΔεT＝α(T)ΔT；
fM＝1-EXP[-(MS-)]；
in the formula: delta epsilon is a welding residual stress field; delta epsilonTIs thermoelastic strain; delta epsilonΔVIs the volume strain; delta epsilontripIs a phase change plastic strain; f. ofAAnd fMAustenite volume fraction and martensite volume fraction, respectively, T is the current temperature, AC1To the austenite transformation temperature, AC3The austenite transformation end temperature, A and D are material dependent coefficients, MSIs the martensitic transformation temperature, C is the material constant, Δ fKThe volume fraction of the K phase is the volume strain when the phase is completely changed, K is the trip coefficient, S is the partial stress, and zeta is the phase change rate; α (T) is the temperature dependent linear expansion coefficient, Δ T is the temperature change amplitude, and f' (ζ) is the derivative of the saturation function.
As a preferred technical scheme, if the requirement of error within 5% is met, the first and second main heating zones are heated to the heat preservation temperature, the corresponding auxiliary heating zone is heated when the main heating zone begins to cool, and the auxiliary heating zone begins to cool after the main heating zone cools to a certain temperature; if the error requirement within 5 percent is not met, the oxyacetylene flame temperature is adjusted, and the oxyacetylene flame is reapplied until the error requirement within 5 percent is met.
The invention has the advantages and positive effects that:
the method is combined with a finite element numerical simulation calculation means to calculate the spatial distribution state of the node residual stress, then a local heat source is applied to a tensile stress area in a targeted manner to heat, the yield strength of the material is reduced along with the temperature rise of the material in the heating area, and the residual stress is released, so that the residual tensile stress is reduced or uniform, the rigidity, the strength, the stability and the fatigue life of the orthotropic steel bridge deck are improved, and the safety guarantee is provided for the normal operation of the in-service bridge.
Description of the drawings:
FIG. 1 is a system diagram of the present invention;
FIG. 2 is a schematic view of the regulation of the residual stress of the weld of the U-rib-cover plate joint of the present invention;
FIG. 3 is a schematic view of the residual stress control of the weld joint of the cover plate-U rib-diaphragm joint of the present invention;
FIG. 4 is a diagram illustrating the steps of the present invention;
FIG. 5 is a flow chart of the present invention.
In the figure, 1, U rib-cover plate; 11. a first primary heating zone; 12. a first secondary heating zone; 2. cover plate-U rib-diaphragm plate; 21. a second primary heating zone; 22. a second secondary heating zone; 3. an oxyacetylene flame; 4. an intelligent data processing center; 5. an infrared thermometer; 6. an X-ray diffractometer.
Detailed Description
The drawings in the embodiments of the invention will be combined; the technical scheme in the embodiment of the invention is clearly and completely described; obviously; the described embodiments are only some of the embodiments of the invention; rather than all embodiments. Based on the embodiments of the invention; all other embodiments obtained by a person skilled in the art without making any inventive step; all fall within the scope of protection of the present invention.
As shown in fig. 1 to 5, the invention provides a multi-point distributed heat source welding residual stress control method for a steel bridge deck, which comprises the following steps:
step 1: carrying out surface pretreatment on the steel bridge deck, removing residual oxides on the surface of the steel bridge deck by adopting manual and mechanical treatment and other modes, removing surface grease and pollutants by using solutions such as acetone and the like, ensuring the flatness of the surface to be adhered, and collecting welding parameters of the steel bridge deck;
step 2: establishing a three-dimensional thermal elastic plastic finite element model of the steel bridge deck according to the collected welding parameters of the steel bridge deck, wherein the establishing conditions of the finite element comprise: geometric models, material thermophysical and mechanical parameters, welding heat sources, unit selection, grid division, boundary conditions and the like, and then welding temperature field and stress field simulation is carried out according to the analysis results; the obtained theoretical heating temperature data is transmitted to the intelligent data processing center 4 through a WiFi network;
because the temperature field belongs to standard three-dimensional nonlinear unstable heat conduction, the three-dimensional heat conduction control equation in the welding process is as follows:
wherein ρ is the material density (kg × m)-3) (ii) a c is the material specific heat capacity (j/(kg k)); λ is the material thermal conductivity (W/(m × k)); t is the heat transfer time(s); t is a temperature field distribution function;
to solve for internal heat source intensity (W/m) in the region3) (ii) a Where ρ, c, λ are functions of temperature T.
In the numerical simulation of the temperature field, the following formula is adopted for calculation, and if the spatial domain omega is dispersed into a finite unit body, the temperature T of a certain unit can be approximately calculated through the node temperature TiInterpolation results in that:
T＝NTe；
in the formula, N is an interpolation function, namely a shape function; t iseIs a time-dependent node temperature vector; t is a node temperature vector; k is a heat transfer matrix; c is a heat capacity matrix; p is a temperature load column vector; K. c, P are all temperature-related variables;
step 3: preliminarily determining the welding residual stress distribution characteristics of the steel bridge deck plate through stress field simulation to obtain the welding residual stress change conditions of different areas away from a welding seam, and defining different heat source regulation and control areas and marking;
the stress field simulation is that welding elastic-plastic finite element analysis is carried out on the basis of the established steel bridge deck finite element model; in the welding stress field simulation, the following formula is adopted for calculation:
dε＝dεe+dεp+dεT
dσ＝Ddε-CdT
wherein d epsilon is the strain increment caused by temperature change; d εeIs the elastic strain increment; d εTIs the temperature induced strain increase; d is a thermo-elastic-plastic matrix; c is a vector related to temperature; d εeIs the plastic strain increment;
is the equivalent strain increment; d ε0The stress increment caused by temperature change; deIs an elastic matrix;
step 4: further refining the heat source regulation and control area, and determining the main heating area and the auxiliary heating area by combining numerical simulation: setting a region 0.8 t-1.2 t away from the U rib-cover plate joint weld as a first main heating region 11 and a region 2 t-4 t away from the U rib-cover plate joint weld as a first auxiliary heating region 12; setting a region 0.8 t-1.2 t away from the joint weld of the cover plate-U rib-diaphragm plate as a second main heating region 21 and a region 2 t-4 t away from the joint weld of the cover plate-U rib-diaphragm plate as a second auxiliary heating region 22; wherein t is the thickness of a welding seam base metal, and temperature measuring points are arranged at the same time; the welding residual stress of the first main heating area 11, the first auxiliary heating area 12, the second main heating area 21, and the second auxiliary heating area 22 can be calculated by the following formula:
Δε＝ΔεT+ΔεΔV+Δεtrip；
ΔεT＝α(T)ΔT；
fM＝1-EXP[-(MS-)]；
in the formula: delta epsilon is a welding residual stress field; delta epsilonTIs thermoelastic strain; delta epsilonΔVIs the volume strain; delta epsilontripIs a phase change plastic strain; f. ofAAnd fMAustenite volume fraction and martensite volume fraction, respectively, T is the current temperature, AC1Austenite transformation temperature, AC3The austenite transformation end temperature, A and D are material dependent coefficients, MSIs the martensitic transformation temperature, C is the material constant, Δ fKThe volume fraction of the K phase is the volume strain during complete phase change, K is the trip coefficient, S is the partial stress, and zeta is the phase change rate; α (T) is the temperature dependent linear expansion coefficient, Δ T is the temperature variation amplitude, f' (ζ) is the derivative of the saturation function;
step 5: adopting oxyacetylene flame with a multi-group moving travelling mechanism, heating the first main heating zone 11, the first auxiliary heating zone 12, the second main heating zone 21 and the second auxiliary heating zone 22 according to set heat source regulation and control parameters, and simultaneously carrying out real-time temperature measurement treatment on the temperature measurement points by using an infrared thermometer 5 to obtain real-time temperature data;
step 6: the intelligent data processing center compares the theoretical heating temperature of step2 with the real-time temperature data of step5, and whether the analysis result is within the specified 5% error range or not;
if the error requirement within 5 percent is met, heating the first main heating area and the second main heating area to the heat preservation temperature, heating the corresponding auxiliary heating area when the main heating area begins to cool, and cooling the auxiliary heating area after the main heating area is cooled to a certain temperature;
if the error requirement within 5 percent is not met, adjusting the temperature of the oxyacetylene flame, and reapplying the oxyacetylene flame 3 until the error requirement within 5 percent is met;
step 7: after one round of heat source regulation and control is completed, heat preservation treatment is carried out on the main heating area and the auxiliary heating area of the steel bridge deck, and the temperature of the regulation and control area is ensured to be slowly reduced;
step 8: and detecting the residual stress of the regulated key part by using an X-ray diffractometer, evaluating whether the regulated residual stress meets the regulation requirement, if not, updating the heat source regulation parameters, returning to step3 and starting a new heat source regulation.
The embodiments of the present invention have been described in detail, but the description is only for the preferred embodiments of the present invention and should not be construed as limiting the scope of the present invention. All equivalent changes and modifications made within the scope of the present invention shall fall within the scope of the present invention.
Claims (7)
1. A multipoint distributed heat source welding residual stress regulation and control method for a steel bridge deck is characterized by comprising the following steps:
step 1: carrying out surface pretreatment on the steel bridge deck plate, removing residual oxides, surface grease and pollutants on the surface of the steel bridge deck plate, ensuring the flatness of the surface to be pasted, and collecting welding parameters of the steel bridge deck plate;
step 2: establishing a three-dimensional thermal elastic plastic finite element model of the steel bridge deck according to the collected welding parameters of the steel bridge deck, simulating a welding temperature field according to an analysis result, and transmitting the obtained theoretical heating temperature data to an intelligent data processing center through a WiFi network;
step 3: preliminarily determining the distribution characteristics of the welding residual stress of the steel bridge deck plate through welding stress field simulation to obtain the change conditions of the welding residual stress in different areas away from a welding seam, and defining different heat source regulation and control areas and making marks;
step 4: further refining the heat source regulation and control area, determining a main heating area and an auxiliary heating area by combining numerical simulation, wherein the main heating area is positioned at a position which is 0.6 t-1.2 t close to a welding seam area, t is the thickness of a base material, the auxiliary heating area is positioned at a position which is 2 t-4 t far away from the welding seam area, and the range of the main heating area and the auxiliary heating area is adjusted according to the actual condition;
step 5: heating the main heating area and the auxiliary heating area by using oxyacetylene flame, and simultaneously carrying out real-time temperature measurement treatment on the temperature measurement points by using an infrared thermometer to obtain real-time temperature data;
step 6: the intelligent data processing center compares the theoretical heating temperature of step2 with the real-time temperature data of step5, and whether the analysis result is within the specified error range or not is judged.
step 7: after one round of heat source regulation and control is completed, heat preservation treatment is carried out on the main heating area and the auxiliary heating area of the steel bridge deck, and the temperature of the regulation and control area is ensured to be slowly reduced;
step 8: and detecting the residual stress of the regulated key part by using an X-ray diffractometer, evaluating whether the regulation requirement is met, if not, updating the heat source regulation parameters, returning to step3, and starting a new heat source regulation.
2. The method for regulating and controlling the welding residual stress of the multi-point distributed heat source for the steel bridge deck as recited in claim 1, wherein a temperature field in step2 belongs to standard three-dimensional nonlinear unsteady heat conduction, and a three-dimensional heat conduction control equation in a welding process is as follows:
wherein ρ is the material density (kg × m)-3) (ii) a c is the material specific heat capacity (j/(kg k)); λ is the material thermal conductivity (W/(m × k)); t is the heat transfer time(s); t is a temperature field distribution function;
to solve for internal heat source intensity (W/m) in the region3) (ii) a Where ρ, c, λ are functions of temperature T.
3. The method for regulating and controlling the residual stress of the multi-point distributed heat source welding for the steel bridge deck as claimed in claim 1, wherein the following is adopted in numerical simulation of the temperature field in step2Formula calculation, if the space domain omega is dispersed into a finite unit body, the temperature T of a certain unit can be approximately passed through the node temperature TiInterpolation results in that:
T＝NTe；
in the formula, N is an interpolation function, namely a shape function; t iseIs a time-dependent node temperature vector; t is a node temperature vector; k is a heat transfer matrix; c is a heat capacity matrix; p is a temperature load column vector; K. c, P are all temperature-dependent variables.
4. The method for regulating and controlling the welding residual stress of the multi-point distributed heat source for the steel bridge deck as claimed in claim 1, wherein the welding stress field simulation in step3 is calculated by adopting the following formula:
dε＝dεe+dεp+dεT
dσ＝Ddε-CdT
wherein d epsilon is the strain increment caused by temperature change; d εeIs the elastic strain increment; d εTIs the temperature induced strain increase; d is a thermo-elastic-plastic matrix; c is a vector related to temperature; d εeIs the plastic strain increment;
is the equivalent strain increment; d ε0The stress increment caused by temperature change; deIs an elastic matrix.
5. The method for regulating and controlling the residual stress of the multi-point distributed heat source welding for the steel bridge deck as claimed in claim 1, wherein the determination method of the main heating area and the auxiliary heating area in step4 comprises the following steps: setting a region 0.8 t-1.2 t away from the U rib-cover plate joint weld as a first main heating region and a region 2 t-4 t away from the U rib-cover plate joint weld as a first auxiliary heating region; setting a region 0.8 t-1.2 t away from the joint weld of the cover plate-U rib-diaphragm plate as a second main heating region, and setting a region 2 t-4 t away from the joint weld of the cover plate-U rib-diaphragm plate as a second auxiliary heating region; and t is the thickness of the welding seam base metal, and temperature measuring points are arranged at the same time.
6. The multipoint distributed heat source welding residual stress control method for the steel bridge deck plate as claimed in claim 5, wherein the welding residual stress of the first main heating zone, the first auxiliary heating zone, the second main heating zone and the second auxiliary heating zone in step5 can be calculated by the following formula:
Δε＝ΔεT+ΔεΔV+Δεtrip；
ΔεT＝α(T)ΔT；
in the formula: delta epsilon is a welding residual stress field; delta epsilonTIs thermoelastic strain; delta epsilonΔVIs the volume strain; delta epsilontripIs a phase change plastic strain; f. ofAAnd fMAustenite volume fraction and martensite volume fraction, respectively, T is the current temperature, AC1Austenite transformation temperature, AC3The austenite transformation end temperature, A and D are material dependent coefficients, MSIs the martensitic transformation temperature, C is the material constant, Δ fKThe volume fraction of the K phase is the volume strain when the phase is completely changed, K is the trip coefficient, S is the partial stress, and zeta is the phase change rate; α (T) is the temperature dependent linear expansion coefficient, Δ T is the temperature change amplitude, and f' (ζ) is the derivative of the saturation function.
7. The method for regulating and controlling the residual stress of the multi-point distributed heat source welding for the steel bridge panel according to claim 5, wherein if the analysis result meets the error requirement within 5%, the first main heating zone and the second main heating zone are heated to the heat preservation temperature, the corresponding auxiliary heating zone is heated when the main heating zone begins to cool, and the auxiliary heating zone begins to cool after the main heating zone cools to a certain temperature; and if the error requirement within 5 percent is not met, adjusting the temperature of the oxyacetylene flame, and reapplying the oxyacetylene flame until the error requirement within 5 percent is met.
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