CN114662233A - Design method for forging neck flange - Google Patents

Design method for forging neck flange Download PDF

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CN114662233A
CN114662233A CN202210263224.6A CN202210263224A CN114662233A CN 114662233 A CN114662233 A CN 114662233A CN 202210263224 A CN202210263224 A CN 202210263224A CN 114662233 A CN114662233 A CN 114662233A
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flange
forged
neck
section
calculating
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陶青松
余亮
李布辉
朱轶
吕健
龙海波
杨云
郭昊
李宁
汤鹏
战龙龙
凤良
吴勇
朱亚鹏
薛正元
杨志浩
张炜
王闯
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China Energy Engineering Group Jiangsu Power Design Institute Co Ltd
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China Energy Engineering Group Jiangsu Power Design Institute Co Ltd
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    • G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
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    • G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
    • G06F2119/02—Reliability analysis or reliability optimisation; Failure analysis, e.g. worst case scenario performance, failure mode and effects analysis [FMEA]
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    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
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Abstract

The invention discloses a design method for forging a flange with a neck, which comprises the following steps: determining the specification and the number of the flange joint connecting bolts according to the tension borne by the main pipe; determining the inner edge distance and the outer edge distance of the flange bolt according to the specification of the connecting bolt and the construction requirement; calculating the thickness of the flange plate surface according to the tensile force borne by each block bolt; calculating the designed neck bending stress of the forged neck flange according to the main pipe stress and the construction requirement, adjusting the designed forged neck flange based on the calculation result, and if the neck bending stress of the flange is greater than the design strength of steel, further adjusting the neck size of the flange; otherwise, the size of the neck of the flange meets the design requirement. The method adopts the rigidity theory to forge the neck flange, the outer edge of the flange is separated when the flange is pulled, the influence of prying force does not exist, and the axial tension stress mechanism of forging the neck flange is truly reflected.

Description

Design method for forging neck flange
Technical Field
The invention relates to a design method of a forged neck flange, and belongs to the technical field of transmission towers.
Background
With the planning construction of extra-high voltage lines and the application of the same-tower multi-loop technology, the external load of the power transmission iron tower is increased in multiples, and the iron tower structure tends to be large-sized. The steel tube tower has the advantages of simple structure, high integral rigidity and good bearing capacity, and is suitable for being applied to iron towers with large loads. The steel pipe tower popularized and applied in a large-load iron tower can effectively reduce the tower weight, reduce the pole tower root opening, compress a line corridor and reduce the removal and vegetation damage. The closed circular section steel tube has the advantages of good air flow performance, isotropic stress, good torsion resistance, high stable bearing capacity, large bending rigidity, better corrosion resistance effect than that of an opening section, convenience in processing, good visual effect and the like. The steel pipe member is widely applied to the industries of electric power, metallurgy, petroleum, chemical industry, post and telecommunications and the like, particularly, the steel pipe member is widely applied to broadcasting and television towers with 200-300 m heights from quadrangles to octagons in broadcasting and television systems, and the steel pipe member is quite common and becomes the main structural form of the television towers.
From the design experience in foreign countries, most of the heavy-load towers in developed countries adopt steel tube tower structures. From the 90 s of the last century, Japan has used the steel tube tower structure in high-voltage and extra-high voltage engineering, and has adopted the structure system in 1000kV extra-high voltage line and transmission high tower, and has developed experimental research and theoretical analysis about the application of steel tube tower engineering; steel pipe towers are also widely used in korea on 750kV transmission lines. The application of the steel pipe tower in the power transmission iron tower in China is relatively late, the domestic steel pipe tower structure is mostly used in a large-span and 500kV double-loop power transmission iron tower and a part of power transformation frameworks, and a 1000kV double-loop ultra-high voltage power transmission line completely adopts the steel pipe tower structure.
The main material connection of the power transmission steel pipe tower usually adopts flange joints, and a typical bolt-flange connection mode comprises a bolt assembly, a flange plate, a gasket and the like. Common flange forms are rigid flanges, flexible flanges and forged necked flanges. The rigid flange has better connection rigidity and bearing capacity characteristics, but the welding workload is large, the welding of the stiffening ribs is manual welding, and the local part of the node has larger welding residual stress; the flexible flange plate has small connecting rigidity and large deformation, and is generally used as a secondary rod member node; the diameter and the wall thickness of a neck opening of a forged connecting steel pipe with a neck flange and a neck welding flange are basically consistent, the forged connecting steel pipe with the neck flange is connected with the neck welding flange through a butt welding seam, the neck flange is provided with a section of straight neck section and a slope changing section, the stress of the flange is coordinated, the structure of the flange is more reasonable, the stress performance and the connection rigidity of a stiffening flange are improved, and if the neck flange is reasonably designed, the connection rigidity of the stiffening flange is between the stiffening flange and the stiffening flange. The neck flange connection is forged without welding stiffening ribs, and the butt welding seam can be mechanically welded, so that the heavy work of manual welding of stiffening flange stiffening ribs can be solved, and the manufacturing efficiency and the mechanization efficiency are improved. The existing design method for forging the neck flange is established based on the design theory of the flexible flange, namely, prying force exists between the outer edges of the flange plates when a main pipe is pulled, and due to the lever principle, the connecting bolts generate additional tensile force, so that the bolt specification and the flange plate size are increased, and the economical efficiency is poor.
Disclosure of Invention
Aiming at the defects in the existing design technology for forging the flange with the neck, the invention provides a design method for forging the flange with the neck, which does not consider the prying force at the outer edge of the disk surface when the flange is pulled and effectively reduces the pulling force borne by the bolt, thereby reducing the specification of the bolt, reducing the disk surface size of the flange, reducing the quality of the flange and effectively improving the economy and the reliability of the flange joint.
In order to achieve the purpose, the invention adopts the technical scheme that:
the invention provides a design method for a forged neck flange, wherein the design of the forged neck flange comprises the design of main pipe tension, flange plate outer diameter and flange thickness, and the design method comprises the following steps:
calculating through the whole power transmission steel pipe tower structure to obtain the main pipe tension; calculating the specification of the steel pipe according to the tension of the main pipe, and calculating the diameter and the number of the flange joint connecting bolts;
determining the inner edge distance and the outer edge distance of the flange plate bolts according to the specification and the number of the flange node connecting bolts, and determining the size of the flange plate surface based on the inner edge distance and the outer edge distance of the flange plate bolts; the size of the flange plate surface comprises the outer diameter of a flange plate;
calculating the thickness of the flange plate surface according to the size of the flange plate surface and the tension of the main pipe;
the designed neck bending stress of the forged neck flange is calculated and the designed forged neck flange is adjusted based on the calculation.
Further, the method also comprises the following steps:
after the size of the flange plate surface is determined, whether the inner edge distance of the flange plate bolts, the outer edge distance of the bolts and the circumferential distance of the bolts meet the standard construction requirements or not is verified, and if not, the specification and the number of the bolts are determined again.
Further, calculating the thickness of the flange plate surface according to the size of the flange plate surface and the tension of the main pipe, comprises:
the arc length of each block of the flange is calculated as follows:
Figure BDA0003551553810000021
wherein S isdThe arc length of each block is represented, d represents the outer diameter of the flange plate, theta represents the central angle corresponding to each block, and n is the number of bolts;
calculating the radial bending moment of each block flange plate based on the block balance equation as follows:
Figure BDA0003551553810000022
Figure BDA0003551553810000023
wherein, TB0Showing the tension of each block bolt, T being the main pipe tension, B being the inner edge distance of the bolt, MrThe radial bending moment of the flange is represented, and r represents the tangential bending moment coefficient of the flange surface;
calculating the thickness of the flange plate surface as follows:
Figure BDA0003551553810000024
wherein C represents the thickness of the flange plate surface, fyIndicating the design strength of the steel.
Further, the calculating the designed neck bending stress of the forged neck flange comprises:
averagely dividing the section of the forged hubbed flange into 2 equal parts along the diameter, and calculating the bending moment of the flange separator based on a balance equation corresponding to the flange separator;
calculating the center of gravity of the section of the forged hubbed flange, and calculating the section resisting moment of the flange based on the center of gravity of the section of the forged hubbed flange;
and calculating the bending stress of the flange section based on the flange section resisting moment and the flange isolator bending moment.
Further, the balance equation corresponding to the flange isolator is as follows:
M0+0.5T(yt-yb)＝0，
Figure BDA0003551553810000031
Figure BDA0003551553810000032
wherein M is0Indicating flange isolator bending moment, ytDenotes the distance of the main pipe wall from the center line, ybThe distance from the acting point of the resultant force of the bolt group to the center line is shown, and K represents the diameter of the flange bolt circle.
Further, said calculating the center of gravity of the cross section of the forged hubbed flange comprises:
dividing the section of the forged hubbed flange into a standard triangle and a standard rectangle, and calculating the gravity center of the section of the forged hubbed flange as follows:
Figure BDA0003551553810000033
wherein, yO'Showing the distance, A, between the center of gravity of the cross-section of the forged hubbed flange and the X-axis1、A2、A3The area of 3 zones divided for the flange cross section respectively,
Figure BDA0003551553810000034
the distances between the center of gravity and the X axis of 3 areas divided by the flange section.
Further, the flange section bending stress is calculated as follows:
Figure BDA0003551553810000035
wherein M is0Indicating flange isolator bending moment, WyRepresenting the flange section resisting moment, K representing the flange bolt circle diameter, H representing the flange section height, IyRepresenting the flange section moment of inertia, yO'Showing the distance of the center of gravity of the cross section of the forged hubbed flange from the X-axis.
Further, the adjusting the designed forged neck flange based on the calculation result includes:
if the bending stress of the section of the flange is greater than the design strength of steel, the width of the neck of the flange needs to be further adjusted; and if the bending stress of the section of the flange is not more than the design strength of the steel, the size of the neck of the flange meets the design requirement.
Compared with the prior art, the invention has the following beneficial effects:
the method adopts the rigidity theory to forge the design of the flange with the neck, namely, the outer edge of the flange plate is separated when the flange plate is pulled, the influence of prying force does not exist, and the pulling force borne by the bolt is effectively reduced, so that the specification of the bolt is reduced, the size of the disk surface of the flange is reduced, the quality of the flange is reduced, and the economy and the reliability of the flange joint are effectively improved. The ultimate bearing capacity of the forged neck flange with the same specification calculated according to the invention is slightly smaller than the test result and the numerical simulation result, and the two are well matched; the method fills the gap of regulation specification, is reasonable in calculation method and reliable in calculation result, and is beneficial to guiding engineering design.
Drawings
FIG. 1 is a flow chart of a forged neck flange design provided by the present invention;
FIG. 2 is a schematic view of the flange plate of each block of the present invention;
FIG. 3 is a schematic cross-sectional force diagram of a flange according to the present invention;
FIG. 4 is a schematic view of the center of gravity of a flange section according to the present invention;
FIG. 5 is a cross-sectional dimension view of an example forged neck flange design in an embodiment of the present invention;
FIG. 6 is a finite element simulated stress distribution plot of an example forged neck flange design in an embodiment of the present invention;
FIG. 7 is a finite element simulated disk face contact stress profile of an example forged neck flange design in accordance with an embodiment of the present invention.
Detailed Description
The invention is further described below with reference to the accompanying drawings. The following examples are only for illustrating the technical solutions of the present invention more clearly, and the protection scope of the present invention is not limited thereby.
One embodiment of the present invention provides a method for designing a forged neck flange, as shown in fig. 1, comprising the steps of:
step one, calculating the uplift force T of the steel pipe component through the whole power transmission steel pipe tower structure, and using the uplift force T as the external input condition of the steel pipe component and the corresponding flange node. Calculating the specification of the steel pipe according to the equal strength principle according to the upper pulling force T, and calculating the diameter d of the flange node connecting bolt0And a number n;
step two, connecting the bolt according to the specification d of the flange joint0Determining the size of the flange plate surface according to the number n, verifying whether the inner edge distance B of the flange plate bolts, the outer edge distance A of the bolts and the circumferential distance of the bolts meet the standard construction requirements or not, and if not, adjusting the size of the corresponding flange plate surface; and judging whether Nmax < Ntb is true, if true, the bolt configuration meets the requirement, and if not, the bolt specification needs to be adjusted again.
Step three, determining the size of the flange disc surface and the tension T applied to the corresponding bolt of each block of the flange according to the step twoB0Calculating the thickness C of the flange surface, wherein the stress schematic diagram of each block flange plate is shown in figure 2, and the specific calculation method is as follows:
arc length of each block of the flange:
Figure BDA0003551553810000041
wherein: sdRepresenting the arc length of each block, d representing the outer diameter of the main pipe, and theta representing the central angle corresponding to each block; and n is the number of bolts.
Balance equation for each block:
Mr+2Mt sin(θ/2)＝TB0·B，
wherein: t is a unit ofB0The tensile force applied to each block bolt is shown,
Figure BDA0003551553810000051
b represents the inner edge distance of the bolt, MrRepresenting radial bending moment of flange, MtIndicating tangential bending moment of flange, Mt＝rMrAnd r represents the tangential bending moment coefficient of the flange plate surface.
Radial bending moment of each block flange:
Figure BDA0003551553810000052
thickness of the flange plate surface:
Figure BDA0003551553810000053
wherein: c represents the thickness of the flange face, fyIndicating the design strength of the steel.
Step four, calculating the bending stress of the neck of the flange according to the tensile force borne by the main pipe and the construction requirement, adjusting the size of the neck of the designed forged flange,
the schematic diagram of the stress of the section of the flange is shown in fig. 3, and the specific calculation method is as follows:
the cross section of the forged flange with the neck is averagely divided into 2 equal parts along the diameter, each part bears the main pipe with the tension of T/2, the bolt group with the tension of T/2 and the bending moment of M0The balance equation corresponding to each isolator is:
M0+0.5T(yt-yb)＝0，
Figure BDA0003551553810000054
Figure BDA0003551553810000055
wherein: y istDenotes the distance of the main pipe wall from the center line, ybRepresents the distance from the acting point of the resultant force of the bolt group to the center line, M0The bending moment borne by the flange insulator is shown, and K represents the diameter of a flange bolt circle.
As shown in FIG. 4, for a forged neck flange section, the section center of gravity is calculated as follows:
Figure BDA0003551553810000056
in fig. 4, O1, O2, and O3 indicate the gravity center positions of 3 regions of the flange cross section divided along the dotted line, and O' indicates the gravity center position of the flange cross section. A. the1、A2、A3Showing the area of 3 zones of the flange cross-section divided along the dashed line,
Figure BDA0003551553810000057
showing the distance of the center of gravity of 3 areas of the flange cross section divided along the dotted line from the X-axis.
Bending stress sigma of flange sectionf：
Figure BDA0003551553810000061
Wherein: h denotes the height of the flange section, IyRepresenting the flange section moment of inertia, WyRepresenting the flange section moment of resistance.
If the flange section bending stress sigmafGreater than the design strength f of steelyThen it is necessary to furtherAdjusting the size of the neck of the flange, specifically adjusting the width of the neck of the flange; if the flange section bending stress sigmafNot greater than the design strength f of steelyAnd the size of the neck of the flange meets the design requirement.
Example (b):
as shown in FIG. 5, the main pipe specification phi 356 multiplied by 8 corresponds to the forged neck flange node, and 20M24 bolts with the diameter d024mm, the effective cross-sectional area of the bolt is 353mm2The central angle corresponding to the adjacent bolts is 18 degrees, 8.8-level high-strength bolts are adopted, the design value of the tensile strength is 400MPa, and the design value of the tensile bearing capacity of a single bolt is 141.2 kN. The main pipe and the flange are made of Q420, and the design tension T of the main pipe is 2623 kN. The ring flange external diameter is 478mm, and the bolt circle diameter is 430mm, and flange neck root diameter is 370mm, and flange neck tip external diameter is 370mm, and flange neck tip thickness is 10mm, and the ring flange internal diameter is 300mm, and ring flange thickness is 32mm, and the flange cross-section height is 100 mm. The checking process of the section of the forged flange is as follows:
the node bolt is stressed:
Figure BDA0003551553810000062
bolt outside margin:
Figure BDA0003551553810000063
inner edge distance of the bolt:
Figure BDA0003551553810000064
arc length of each block of the flange:
Figure BDA0003551553810000065
radial bending moment of each block flange:
Figure BDA0003551553810000066
thickness of the flange plate surface:
Figure BDA0003551553810000067
bending moment stress of the flange section:
Figure BDA0003551553810000068
as shown in fig. 6 to 7, the flange size is determined by using the design tension of the main pipe as an external input condition and the thickness of the flange plate as a response index. It can be seen that under the same tension input condition obtained by calculation according to said invention, the maximum simulated stress of flange section is basically identical to the calculated stress of section, and the external edge of flange has no contact stress, so that it can indicate that the external edge of flange is separated, and is in accordance with the rigidity theory adopted by said invention. The method fills the gap of regulation specifications, is reasonable in calculation method and reliable in calculation result, is beneficial to guiding the design of actual engineering, and can be popularized and applied in the actual engineering.
The above description is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, several modifications and variations can be made without departing from the technical principle of the present invention, and these modifications and variations should also be regarded as the protection scope of the present invention.

Claims (8)

1. A method for designing a forged neck flange is characterized in that the forged neck flange design comprises the design of main pipe tension, flange plate outer diameter and flange thickness, and the design method comprises the following steps:
calculating to obtain the main pipe tension through the whole power transmission steel pipe tower structure; calculating the specification of the steel pipe according to the tension of the main pipe, and calculating the diameter and the number of the flange joint connecting bolts;
determining the inner edge distance and the outer edge distance of the bolts of the flange plate according to the specification and the number of the flange node connecting bolts, and determining the surface size of the flange plate based on the inner edge distance and the outer edge distance; the size of the flange plate surface comprises the outer diameter of a flange plate;
calculating the thickness of the flange plate surface according to the size of the flange plate surface and the tension of the main pipe;
and calculating the neck bending stress of the designed forged neck flange, and adjusting the designed forged neck flange based on the calculation result.
2. A method of designing a forged hubbed flange according to claim 1, further comprising:
after the size of the flange plate surface is determined, whether the inner edge distance of the flange plate bolts, the outer edge distance of the bolts and the circumferential distance of the bolts meet the standard construction requirements or not is verified, and if not, the specification and the number of the bolts are determined again.
3. The method for designing a forged necked flange according to claim 1, wherein the step of calculating the thickness of the flange plate surface according to the size of the flange plate surface and the tension of the main pipe comprises the following steps:
the arc length of each block of the flange is calculated as follows:
Figure FDA0003551553800000011
wherein S isdThe arc length of each block is represented, d represents the outer diameter of the flange plate, theta represents the central angle corresponding to each block, and n is the number of bolts;
calculating the radial bending moment of each block flange plate based on the block balance equation as follows:
Figure FDA0003551553800000012
Figure FDA0003551553800000013
wherein, TB0Showing the tension of each block bolt, T being the main pipe tension, B being the inner edge distance of the bolt, MrRepresenting radial bending moment of the flange plate, and r represents tangential bending moment coefficient of the flange plate surface;
calculating the thickness of the flange plate surface as follows:
Figure FDA0003551553800000014
wherein C represents the thickness of the flange plate surface, fyIndicating the design strength of the steel.
4. A method of designing a forged neck flange according to claim 3 wherein said calculating a designed neck bending stress of the forged neck flange comprises:
averagely dividing the section of the forged hubbed flange into 2 equal parts along the diameter, and calculating the bending moment of the flange separator based on a balance equation corresponding to the flange separator;
calculating the center of gravity of the section of the forged hubbed flange, and calculating the section resisting moment of the flange based on the center of gravity of the section of the forged hubbed flange;
and calculating the bending stress of the flange section based on the flange section resisting moment and the flange isolator bending moment.
5. A method of designing a forged hubbed flange according to claim 4, wherein the balance equation for the flange isolator is:
M0+0.5T(yt-yb)＝0，
Figure FDA0003551553800000021
Figure FDA0003551553800000022
wherein M is0Indicating flange isolator bending moment, ytDenotes the distance of the main pipe wall from the center line, ybThe distance from the acting point of the resultant force of the bolt group to the center line is shown, and K represents the diameter of the flange bolt circle.
6. A method of designing a forged hubbed flange according to claim 4, wherein said calculating a forged hubbed flange section center of gravity comprises:
dividing the section of the forged hubbed flange into a standard triangle and a standard rectangle, and calculating the gravity center of the section of the forged hubbed flange as follows:
Figure FDA0003551553800000023
wherein, yO'Showing the distance, A, between the center of gravity of the cross-section of the forged hubbed flange and the X-axis1、A2、A3The area of 3 zones divided for the flange cross section respectively,
Figure FDA0003551553800000024
the distances between the center of gravity and the X axis of 3 areas divided by the flange section respectively.
7. A method of designing a forged hubbed flange according to claim 4, wherein said flange section bending stresses are calculated as follows:
Figure FDA0003551553800000025
wherein, M0Indicating flange isolator bending moment, WyRepresenting the flange section resisting moment, K representing the flange bolt circle diameter, H representing the flange section height, IyRepresenting the flange section moment of inertia, yO'Showing the distance of the center of gravity of the cross section of the forged hubbed flange from the X-axis.
8. A method as claimed in claim 4, wherein the step of adjusting the designed forged hubbed flange based on the calculation comprises:
if the bending stress of the flange section is greater than the designed strength of the steel, the width of the flange neck needs to be further adjusted; and if the bending stress of the section of the flange is not more than the design strength of the steel, the neck of the flange meets the design requirement.
CN202210263224.6A 2022-03-17 2022-03-17 Design method for forging neck flange Pending CN114662233A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116227241A (en) * 2023-05-08 2023-06-06 长沙海贝智能科技有限公司 Method for determining optimal machining positioning position of forged shaft and forged shaft machining method

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116227241A (en) * 2023-05-08 2023-06-06 长沙海贝智能科技有限公司 Method for determining optimal machining positioning position of forged shaft and forged shaft machining method

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