CN115455771B - Deformation error control method caused by temperature effect in manufacturing of large-section steel box girder - Google Patents
Deformation error control method caused by temperature effect in manufacturing of large-section steel box girder Download PDFInfo
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Abstract
The invention provides a deformation error control method caused by temperature effect in the manufacture of a large-section steel box girder, which belongs to the technical field of steel box girder manufacture, and is characterized in that a top plate and a bottom plate are cut according to longitudinal variation of each point of the top plate and the bottom plate respectively; determining the coordinates of the end parts of the plates at the actual splicing temperature according to the variation of the actual splicing temperature and the reference splicing temperature and the linear expansion coefficient of the plates, and splicing the plates according to the coordinates of the end parts of the plates at the actual splicing temperature; determining the difference value of the top crack variable quantity and the bottom crack variable quantity of the contact ends of the small-section steel box girders according to the difference value, and correcting the size of the top plate of the contact ends of the adjacent two small-section steel box girders; by reasonably controlling the deformation errors existing in each step in the manufacturing process of the large-section steel box girder, the influence caused by the environmental temperature and the welding temperature in the manufacturing process of the large-section steel box girder is reduced, and the accurate and rapid manufacturing of the large-section steel box girder is ensured.
Description
Technical Field
The invention relates to the technical field of steel box girder manufacturing, in particular to a deformation error control method caused by a temperature effect in the manufacture of a large-section steel box girder.
Background
The steel box girder has the advantages of light dead weight, high bearing capacity, convenient construction and the like, and is widely applied to the large-span steel bridge. The steel box girder bridge has a plurality of construction methods, and the large-section hoisting method has the advantages of high construction speed, high construction quality and safety and the like, and is particularly suitable for a river-crossing and sea-crossing super-large bridge. The large-section hoisting construction method is that after the prefabrication of the small sections of the steel box girder is completed, the small sections are directly assembled into whole span large sections in a factory, and after the large sections are transported to a bridge site position through a transport vehicle or a transport ship, the whole steel box girder is directly hoisted to a design position by utilizing large-scale hoisting tools such as a floating crane.
In the manufacturing process of the large-section steel box girder, deformation caused by the environmental temperature and welding temperature effect is difficult to calculate accurately, which causes manufacturing errors, and no accurate calculation and control method exists at present. In addition, once the girth welding between the beam sections is completed after the large-section steel box beam is hoisted, the final bridge forming state is determined, and then the internal force and the linear adjustment are difficult to effectively perform. Therefore, reasonably and effectively controlling the deformation error caused by the temperature effect in the manufacturing process of the large-section steel box girder is a main measure for ensuring the reasonable bridge formation and internal force state.
Disclosure of Invention
The invention aims to provide a deformation error control method caused by a temperature effect in the manufacture of a large-section steel box girder, so that the influence caused by the environmental temperature and the welding temperature in the manufacture process of the large-section steel box girder is reduced, and the accurate and rapid manufacture of the large-section steel box girder is ensured.
In order to achieve the above object, the present invention provides the following solutions:
the method for controlling deformation errors caused by temperature effects in manufacturing of large-section steel box girders comprises the steps that the large-section steel box girders are formed by welding a plurality of sections of small-section steel box girders, the small-section steel box girders are formed by splicing a plurality of plates, and the plates comprise a top plate and a bottom plate; a plurality of U-shaped ribs are welded on the surface of the top plate and the surface of the bottom plate; the deformation error control method comprises the following steps:
finite element analysis is respectively carried out on the model of the top plate and the model of the bottom plate in a U-shaped rib welding state, and the simulated longitudinal variation of each transverse point of the top plate in the U-shaped rib welding state and the simulated longitudinal variation of each transverse point of the bottom plate in the U-shaped rib welding state are determined; the simulated longitudinal variation is the variation of the plate in the extending direction of the U-shaped rib; the transverse direction is a direction perpendicular to the extending direction of the U-shaped rib;
determining the longitudinal dimension of the top plate and the longitudinal dimension of the bottom plate according to the simulated longitudinal variation of each transverse point of the top plate in the U-shaped rib welding state and the simulated longitudinal variation of each transverse point of the bottom plate in the U-shaped rib welding state, so as to obtain the simulated longitudinal dimension of the top plate and the simulated longitudinal dimension of the bottom plate; the simulated longitudinal dimension of the top plate and the simulated longitudinal dimension of the bottom plate are respectively used for guiding the cutting of the top plate and the bottom plate in practice so that the longitudinal dimension of the top plate or the bottom plate reaches a preset dimension after the U-shaped rib welding is completed;
for any plate, determining the size change of the plate at the actual splicing temperature according to the size of the plate at the reference splicing temperature, the linear expansion coefficient of the plate and the change of the actual splicing temperature and the reference splicing temperature, and obtaining the simulated size change of the plate;
determining the coordinates of the end part of the plate at the actual splicing temperature according to the simulated size variation of the plate to obtain the simulated coordinates of the end part of the plate; the simulation coordinates of the end parts of the plates are used for guiding the positions of the end parts of the plates when the plates are spliced, so that the end parts of the plates are accurately spliced with the starting point of the next plate;
establishing a finite element model of two adjacent small-section steel box girders in a welding state, and carrying out finite element analysis according to an actual welding procedure to determine a top crack variable quantity and a bottom crack variable quantity between the two small-section steel box girders so as to obtain a simulated top crack variable quantity and a simulated bottom crack variable quantity between the two small-section steel box girders;
determining the difference value of the simulated top crack variable quantity and the simulated bottom crack variable quantity according to the simulated top crack variable quantity and the simulated bottom crack variable quantity, and obtaining a simulated crack variable quantity difference value;
correcting the sizes of the top plates of the contact ends of the two small-section steel box girders according to the simulated crack variation difference value to obtain the respective simulated top plate sizes of the two small-section steel box girders; the simulated top plate size of the small-section steel box girder is used for guiding the cutting of the small-section steel box girder, so that the length of the top plate in the small-section steel box girder after the actual welding is the same as the length of the bottom plate.
Optionally, the following formula is used to determine the simulated longitudinal variation of each point in the transverse direction of the top sheet:
wherein f (x) is the simulated longitudinal variation distribution of each point in the transverse direction of the top plate, x is any point in the transverse direction of the top plate, a is the transverse interval of the U-shaped rib, A 0 、A 1 、A 2 、A 3 、B 0 、B 1 、B 2 、B 3 、C 0 、C 1 、C 2 、C 3 Fitting coefficients; and the central line of the U-shaped rib is a starting point 0, and the longitudinal variation is symmetrically distributed along the central line of the U-shaped rib.
Optionally, determining the longitudinal dimension of the top plate and the longitudinal dimension of the bottom plate according to the simulated longitudinal variation of the lateral points of the top plate in the U-rib welding state and the simulated longitudinal variation of the lateral points of the bottom plate in the U-rib welding state to obtain the simulated longitudinal dimension of the top plate and the simulated longitudinal dimension of the bottom plate specifically includes:
if the simulated longitudinal variation of each transverse point of the top plate in the U-shaped rib welding state is z, shortening the longitudinal dimension of the top plate by z before U-shaped rib welding is carried out on the top plate, so as to obtain the simulated longitudinal dimension of the top plate;
if the simulated longitudinal variation of each transverse point of the top plate in the U-shaped rib welding state is-z, extending the longitudinal dimension of the top plate by z before U-shaped rib welding is carried out on the top plate, so as to obtain the simulated longitudinal dimension of the top plate;
if U-shaped ribThe simulated longitudinal variation of each transverse point of the bottom plate in the welding state is z 1 The longitudinal dimension of the bottom plate is shortened by z before U-shaped rib welding is carried out on the bottom plate 1 Obtaining the simulated longitudinal dimension of the bottom plate;
if the simulated longitudinal variation of each transverse point of the bottom plate in the U-shaped rib welding state is-z 1 The longitudinal dimension of the bottom plate is prolonged by z before U-shaped rib welding is carried out on the bottom plate 1 The simulated longitudinal dimension of the bottom sheet is obtained.
Optionally, the dimensional change of the sheet material at the actual splicing temperature is determined according to the following formula:
Δl＝αΔTl
wherein Deltal is the size variation of the plate at the actual splicing temperature, alpha is the linear expansion coefficient of the plate, deltaT is the temperature variation of the reference splicing temperature and the actual splicing temperature, and l is the size of the plate at the reference splicing temperature.
Optionally, the amount of change in coordinates of the sheet ends at the actual splice temperature is determined according to the following equation:
Δx＝Δl cosβ
Δy＝Δl sinβ
wherein Δx is the x-axis coordinate variation of the end of the plate at the actual splicing temperature, Δy is the y-axis coordinate variation of the end of the plate at the actual splicing temperature, Δl is the analog dimension variation of the plate at the actual splicing temperature, and β is the placement angle of the plate.
Optionally, the gap variation difference is determined according to the following formula:
δ＝δ top -δ bottom
wherein delta top To simulate the amount of roof crack variation, delta bottom To simulate the bottom gap variation, δ is the gap variation difference.
Optionally, correcting the sizes of the top plates at the contact ends of the two small-section steel box girders according to the simulated gap variation difference value to obtain the respective simulated top plate sizes of the two small-section steel box girders, which specifically comprises:
for any small-section steel box girder, shortening the size of the top plate at the contact end of the small-section steel box girder and the other small-section steel box girder by delta to obtain the respective simulated top plate size of the two small-section steel box girders.
Optionally, correcting the sizes of the top plates at the contact ends of the two small-section steel box girders according to the simulated gap variation difference value to obtain the respective simulated top plate sizes of the two small-section steel box girders, which specifically comprises:
and respectively shortening the size of the top plate at the contact end of the two small-section steel box girders by delta/2 to obtain the respective simulated top plate size of the two small-section steel box girders.
Corresponding to the deformation error control method, the invention also provides a deformation error control system caused by temperature effect in the manufacture of the large-section steel box girder, and the deformation error control system executes the deformation error control method caused by temperature effect in the manufacture of the large-section steel box girder when being run by a computer.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects:
according to the deformation error control method caused by the temperature effect in the manufacture of the large-section steel box girder, firstly, when the U-shaped ribs are welded on the surfaces of the top plate and the bottom plate, the top plate and the bottom plate are cut according to the longitudinal variation of each point of the top plate and the longitudinal variation of each point of the bottom plate respectively, so that the large error does not exist at the contact end of other plates after the U-shaped ribs are welded; secondly, in the process of splicing the plates, determining the length variation of each plate at the actual splicing temperature and the coordinates of the end parts of the plates according to the variation of the actual splicing temperature and the reference splicing temperature and the linear expansion coefficient of the plates, and splicing the plates according to the plate coordinates at the actual splicing temperature, so as to avoid splicing errors caused by the influence of the environmental temperature when the plates are spliced according to the coordinates designed at the reference splicing temperature; finally, when each small-section steel box girder is welded into a large-section steel box girder, determining a difference value between the two according to the top crack variable quantity and the bottom crack variable quantity of the contact end, and correcting the size of the top plate of the contact end of two adjacent small-section steel box girders under the condition that the bottom plate is kept unchanged, so that the large-section steel box girders are prevented from deviating from manufacturing lines along with the splicing length due to the fact that the welding procedures and the welding workload of the top plate and the bottom plate of the adjacent small-section steel box girders are different; by reasonably controlling the deformation errors existing in each step in the manufacturing process of the large-section steel box girder, the influence caused by the environmental temperature and the welding temperature in the manufacturing process of the large-section steel box girder is reduced, and the accurate and rapid manufacturing of the large-section steel box girder is ensured.
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In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a flow chart of a method for controlling deformation errors caused by temperature effects in the manufacture of a large-section steel box girder according to embodiment 1 of the present invention;
fig. 2 is a schematic structural diagram of a steel box girder in the deformation error control method provided in embodiment 1 of the present invention;
fig. 3 is a schematic diagram of a large-section steel box girder in the deformation error control method provided in embodiment 1 of the present invention;
fig. 4 is a cross-sectional view of the deformation error control method according to embodiment 1 of the present invention when welding the U-shaped rib;
FIG. 5 is a top view of the deformation error control method according to embodiment 1 of the present invention when welding U-shaped ribs;
fig. 6 is a schematic diagram of deformation caused by ambient temperature in the deformation error control method according to embodiment 1 of the present invention;
fig. 7 is a schematic diagram illustrating deformation generated during welding between small-section steel box girders in the deformation error control method provided in embodiment 1 of the present invention;
fig. 8 is a schematic structural diagram of a deformation error control system caused by temperature effect in manufacturing a large-section steel box girder according to embodiment 2 of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The invention aims to provide a deformation error control method caused by a temperature effect in the manufacture of a large-section steel box girder, so that the influence caused by the environmental temperature and the welding temperature in the manufacture process of the large-section steel box girder is reduced, and the accurate and rapid manufacture of the large-section steel box girder is ensured.
In order that the above-recited objects, features and advantages of the present invention will become more readily apparent, a more particular description of the invention will be rendered by reference to the appended drawings and appended detailed description.
Example 1:
the embodiment provides a deformation error control method caused by temperature effect in the manufacture of a large-section steel box girder, as shown in a flow chart in fig. 1, the deformation error control method comprises the following steps:
the large-section steel box girder consists of a plurality of small-section steel box girders by welding, as shown in fig. 2, wherein each section belongs to one small-section steel box girder, and a plurality of small-section steel box girders jointly form one large-section steel box girder; as shown in fig. 3, the small-section steel box girder is formed by splicing a plurality of plates, wherein the plates comprise a top plate and a bottom plate; the surface of the top plate and the surface of the bottom plate are welded with a plurality of U-shaped ribs; the plates at the top and bottom of the small-section steel box girder are U-rib stiffening plates, and U-shaped ribs are required to be welded on the surfaces of the plates.
As shown in fig. 4 and 5, the temperature effect during the welding process of the U-shaped rib and the top and bottom plates will cause the longitudinal deformation of the top and bottom plates to be the z-axis direction in the figure, for this purpose, it is necessary to accurately simulate the longitudinal deformation of the top and bottom plates of the small-section steel box girder caused by the welding temperature effect, and then consider the longitudinal deformation reversely into the cutting dimensions of the top and bottom plates of the steel box girder, so as to counteract the longitudinal deformation caused by the welding temperature effect.
S1, determining the simulated longitudinal variation of each transverse point of the plate through finite element analysis;
finite element analysis is respectively carried out on the model of the top plate and the model of the bottom plate in a U-shaped rib welding state, and the simulated longitudinal variation of each transverse point of the top plate in the U-shaped rib welding state and the simulated longitudinal variation of each transverse point of the bottom plate in the U-shaped rib welding state are determined; the simulated longitudinal variation is the variation of the plate in the extending direction of the U-shaped rib; the transverse direction is a direction perpendicular to the extending direction of the U-shaped rib;
in this embodiment, the following formula is used to determine the simulated longitudinal variation of each point in the transverse direction of the top plate:
wherein f (x) is the simulated longitudinal variation distribution of each point in the transverse direction of the top plate, x is any point in the transverse direction of the top plate, a is the transverse interval of the U-shaped rib, A 0 、A 1 、A 2 、A 3 、B 0 、B 1 、B 2 、B 3 、C 0 、C 1 、C 2 、C 3 Fitting coefficients; and the central line of the U-shaped rib is a starting point 0, and the longitudinal variation is symmetrically distributed along the central line of the U-shaped rib.
The formula for determining the simulated longitudinal variation of each transverse point of the top plate is that a U-shaped rib welding finite element model is established according to the actual welding procedure of the top and bottom plates of the small-section steel box girder, after the analysis of the welding process is finished, the longitudinal non-uniform deformation of the top plate is extracted, and the longitudinal variation calculation formula of the top and bottom plates is fitted by using a piecewise cubic polynomial.
S2, determining the simulated longitudinal dimension of the plate according to the simulated longitudinal variation of each transverse point of the plate;
determining the longitudinal dimension of the top plate and the longitudinal dimension of the bottom plate according to the simulated longitudinal variation of each point of the top plate in the U-shaped rib welding state and the simulated longitudinal variation of each point of the bottom plate in the U-shaped rib welding state to obtain the simulated longitudinal dimension of the top plate and the simulated longitudinal dimension of the bottom plate so that the longitudinal dimension of the top plate or the bottom plate reaches a preset dimension after the U-shaped rib welding is finished; the simulated longitudinal dimension of the top plate and the simulated longitudinal dimension of the bottom plate are respectively used for guiding the cutting of the top plate and the bottom plate in practice; in this embodiment, step S2 specifically includes:
s21, if the simulated longitudinal variation of each transverse point of the top plate in the U-shaped rib welding state is z, shortening the longitudinal dimension of the top plate by z before U-shaped rib welding is carried out on the top plate, and obtaining the simulated longitudinal dimension of the top plate;
s22, if the simulated longitudinal variation of each transverse point of the top plate in the U-shaped rib welding state is-z, extending the longitudinal dimension of the top plate by z before U-shaped rib welding is carried out on the top plate, so as to obtain the simulated longitudinal dimension of the top plate;
s23, if the simulated longitudinal variation of each transverse point of the bottom plate in the U-shaped rib welding state is z 1 The longitudinal dimension of the bottom plate is shortened by z before U-shaped rib welding is carried out on the bottom plate 1 Obtaining the simulated longitudinal dimension of the bottom plate;
s24, if the simulated longitudinal variation of each transverse point of the bottom plate in the U-shaped rib welding state is-z 1 The longitudinal dimension of the bottom plate is prolonged by z before U-shaped rib welding is carried out on the bottom plate 1 The simulated longitudinal dimension of the bottom sheet is obtained.
S3, guiding actual cutting and U-shaped rib welding processes according to the simulated longitudinal dimension of the plate;
according to the simulated longitudinal dimension of the top plate and the simulated longitudinal dimension of the bottom plate, respectively carrying out actual cutting and U-shaped rib welding on the top plate and the bottom plate to obtain a welded top plate and a welded bottom plate;
when a plurality of plates are spliced to form a small-section steel box girder, as shown in fig. 6, the temperature of the splicing environment may cause the plates to undergo corresponding expansion deformation, so that the ends of the plates to be butted are displaced, and therefore, correction of such error conditions is required.
S4, determining the simulated size variation of the plate at the actual splicing temperature;
for any plate, determining the size change of the plate at the actual splicing temperature according to the size of the plate at the reference splicing temperature, the linear expansion coefficient of the plate and the change of the actual splicing temperature and the reference splicing temperature, and obtaining the simulated size change of the plate; in this embodiment, the dimensional change of the board at the actual splicing temperature is determined according to the following formula:
Δl＝αΔTl
wherein Deltal is the size variation of the plate at the actual splicing temperature, alpha is the linear expansion coefficient of the plate, deltaT is the temperature variation of the reference splicing temperature and the actual splicing temperature, and l is the size of the plate at the reference splicing temperature.
In another mode, the material of the steel box girder is the same as that of the steel box girder, and the length of the steel box girder at the reference temperature is l 1 Measuring the length change delta l of the steel test piece at the current ambient temperature 1 And then calculating the actual size change of the steel box girder plate according to the following formula:
s5, determining the end simulation coordinates of the plate at the actual splicing temperature;
determining the coordinates of the end part of the plate at the actual splicing temperature according to the simulated size variation of the plate to obtain the simulated coordinates of the end part of the plate so as to accurately splice the end part of the plate with the starting point of the next plate; the simulated coordinates of the plate end are used for guiding the position of the plate end when the plates are spliced; guiding the splicing process of the plates according to the simulated coordinates of the ends of the plates at the actual splicing temperature to obtain a plurality of small-section steel box girders; in this embodiment, the amount of change in the simulated coordinates of the end portion of the sheet material at the actual splicing temperature is first determined according to the following equation:
Δx＝Δl cosβ
Δy＝Δl sinβ
wherein Deltax is the simulated x-axis coordinate variation of the end part of the plate at the actual splicing temperature, deltay is the simulated y-axis coordinate variation of the end part of the plate at the actual splicing temperature, deltal is the simulated size variation of the plate at the actual splicing temperature, and beta is the placement angle of the plate;
and then determining the simulated coordinates of the end part of the plate at the actual splicing temperature according to the simulated coordinate variation of the end part of the plate at the actual splicing temperature and the coordinates of the end part of the plate at the reference splicing temperature.
After determining the simulation coordinates of the end part of the plate at the actual splicing temperature, the specific control measures are as follows: when the positioning is performed on the jig frame, the positioning coordinate correction is performed on the manufacturing length change of the small-section steel box girder caused by the deviation of the ambient temperature and the design reference temperature, and then the lofting operation is performed according to the coordinate value after the temperature difference correction.
When manufacturing a large-section steel box girder, the welding seam shrinkage of the top plate and the bottom plate at the contact end of the small-section steel box girder is different due to the different girth welding procedures and workload of the small-section steel box girder. As shown in FIG. 7, the shrinkage of the weld joint causes the end face corners of the small-section steel box girder to deviate, so that the horizontal corner difference of adjacent sections is changed, and the actual assembly line shape of the large-section steel box girder deviates from the manufacturing line shape along with the assembly length if the horizontal corner difference is not controlled. If the height h of the small-section steel box girder is equal to delta, when the welding seam shrinkage difference of the top plate and the bottom plate is delta, the assembly included angle difference of (-delta/h) rad is caused, and at the moment, the elevation of the end part of the small-section steel box girder with the length L is lower than the theoretical value by delta L/h. It is therefore necessary to control the deformation errors that may occur before the assembly welding of the small section steel box girders.
S6, determining the simulated top crack variable quantity and the simulated bottom crack variable quantity when the two small-section steel box girders are welded through finite element analysis;
establishing a finite element model of two adjacent small-section steel box girders in a welding state, and carrying out finite element analysis according to an actual welding procedure to determine a top crack variable quantity and a bottom crack variable quantity between the two small-section steel box girders so as to obtain a simulated top crack variable quantity and a simulated bottom crack variable quantity between the two small-section steel box girders;
s7, determining the difference value of the simulated top crack variable quantity and the simulated bottom crack variable quantity according to the simulated top crack variable quantity and the simulated bottom crack variable quantity, and obtaining a simulated crack variable quantity difference value; in this embodiment, the gap variation difference is determined according to the following formula:
δ＝δ top -δ bottom
wherein delta top To simulate the amount of roof crack variation, delta bottom To simulate the bottom gap variation, δ is the gap variation difference.
Because the width of the top plate is always larger than that of the bottom plate in the small-section steel box girder, the welding work performed on the edge of the top plate of the small-section steel box girder is larger than that performed on the edge of the bottom plate in actual welding, so that the deformation amount generated by the top plate of the small-section steel box girder is larger than that of the bottom plate of the small-section steel box girder, and the size of the top plate of the small-section steel box girder in contact needs to be shortened.
S8, determining the sizes of top plates of the two small-section steel box girders according to the simulated crack variation difference value, and guiding the welding and assembling process;
and correcting the sizes of the top plates at the contact ends of the two small-section steel box girders according to the simulated crack variation difference value to obtain simulated top plate sizes of the two small-section steel box girders, so that the lengths of the top plates and the bottom plates in the small-section steel box girders after the actual welding are the same, and carrying out a welding assembly process of the small-section steel box girders. In this embodiment, step S8 specifically includes: for any small-section steel box girder, the size of the top plate at the contact end of the small-section steel box girder and another small-section steel box girder is shortened by delta.
As another realizable technical solution, step S8 may specifically be: the dimensions of the top sheet material at the contact end of the two small-section steel box girders are each shortened by delta/2.
Furthermore, the inner circumferential seam welding of large section steel box girders should follow the following principle:
firstly, symmetrically welding butt welds of a top plate, a bottom plate and an inclined bottom plate from the middle to two ends; secondly, butt welding seams of the middle web plate, the side web plates and the side sealing plates are symmetrically welded from bottom to top; thirdly, welding seams of the plates of the same type are symmetrically welded.
In the assembly process of the large-section steel box girder, marking measuring points are made at 1cm positions at two ends of welding lines of adjacent small-section steel box girders, the change amounts of the measuring point distances before welding and after stable welding deformation are measured through a steel ruler, and welding line shrinkage data of top and bottom plates after stable welding deformation of the first-wheel large-section steel box girder are collected so as to verify the effect of a welding process on welding line shrinkage control.
In this embodiment, when the U-shaped rib welding is performed on the surfaces of the top plate and the bottom plate, the top plate and the bottom plate are cut according to the longitudinal variation of each point of the top plate and the longitudinal variation of each point of the bottom plate respectively, so that the contact end of the U-shaped rib welding is prevented from having too large errors after the welding is completed.
And secondly, in the process of splicing the plates, determining the length variation of the plates at the actual splicing temperature and the coordinates of the ends of the plates according to the variation of the actual splicing temperature and the reference splicing temperature and the linear expansion coefficient of the plates, and splicing the plates according to the plate coordinates at the actual splicing temperature, so as to avoid splicing errors caused by the influence of the environmental temperature when the plates are spliced according to the designed coordinates at the reference splicing temperature.
And finally, when each small-section steel box girder is welded into a large-section steel box girder, determining the difference value of the top crack variable quantity and the bottom crack variable quantity of the contact end according to the top crack variable quantity and the bottom crack variable quantity of the contact end, and correcting the size of the top plate of the contact end of two adjacent small-section steel box girders under the condition that the bottom plate is kept unchanged, so that the large-section steel box girders are prevented from being increasingly deviated from manufacturing lines along with the splicing length due to the different welding procedures and welding workload of the top plate and the bottom plate of the adjacent small-section steel box girders.
By reasonably controlling the deformation errors existing in each step in the manufacturing process of the large-section steel box girder, the influence caused by the environmental temperature and the welding temperature in the manufacturing process of the large-section steel box girder is reduced, and the accurate and rapid manufacturing of the large-section steel box girder is ensured.
Example 2:
the method of embodiment 1 of the present invention can also be implemented by means of the architecture of a deformation error control system caused by temperature effects in the manufacture of large-section steel box girders as shown in fig. 8. As shown in fig. 8, the deformation error control system may include: a U-shaped rib welding error correction module, a plate splicing error correction module and a steel box girder welding error correction module; some modules may also have subunits for performing their functions, such as including a simulated longitudinal variation determination unit and a simulated longitudinal dimension determination unit in a U-rib weld error correction module; the board splicing error correction module comprises an analog size determining unit and an analog coordinate determining unit; the steel box girder welding correction module comprises a crack change amount determination unit and a crack change amount difference determination unit. Of course, the architecture shown in fig. 8 is merely exemplary, and in some embodiments, other elements may be added in some modules; in addition, one or at least two components of the system shown in fig. 8 may be omitted, as is practical, when different functions are to be implemented.
Specific examples are employed herein, but the above description is merely illustrative of the principles and embodiments of the present invention, which are presented solely to aid in the understanding of the method of the present invention and its core ideas; it will be appreciated by those skilled in the art that the modules or steps of the invention described above may be implemented by general-purpose computer means, alternatively they may be implemented by program code executable by computing means, whereby they may be stored in storage means for execution by computing means, or they may be made into individual integrated circuit modules separately, or a plurality of modules or steps in them may be made into a single integrated circuit module. The present invention is not limited to any specific combination of hardware and software.
Also, it is within the scope of the present invention to be modified by those of ordinary skill in the art in light of the present teachings. In view of the foregoing, this description should not be construed as limiting the invention.
Claims (8)
1. The method for controlling deformation errors caused by temperature effects in manufacturing of large-section steel box girders comprises the steps that the large-section steel box girders are formed by welding a plurality of sections of small-section steel box girders, the small-section steel box girders are formed by splicing a plurality of plates, and the plates comprise a top plate and a bottom plate; a plurality of U-shaped ribs are welded on the surface of the top plate and the surface of the bottom plate; the deformation error control method is characterized by comprising the following steps:
finite element analysis is respectively carried out on the model of the top plate and the model of the bottom plate in a U-shaped rib welding state, and the simulated longitudinal variation of each transverse point of the top plate in the U-shaped rib welding state and the simulated longitudinal variation of each transverse point of the bottom plate in the U-shaped rib welding state are determined; the simulated longitudinal variation is the variation of the plate in the extending direction of the U-shaped rib; the transverse direction is a direction perpendicular to the extending direction of the U-shaped rib;
determining the longitudinal dimension of the top plate and the longitudinal dimension of the bottom plate according to the simulated longitudinal variation of each transverse point of the top plate in the U-shaped rib welding state and the simulated longitudinal variation of each transverse point of the bottom plate in the U-shaped rib welding state, so as to obtain the simulated longitudinal dimension of the top plate and the simulated longitudinal dimension of the bottom plate; the simulated longitudinal dimension of the top plate and the simulated longitudinal dimension of the bottom plate are respectively used for guiding the cutting of the top plate and the bottom plate in practice so that the longitudinal dimension of the top plate or the bottom plate reaches a preset dimension after the U-shaped rib welding is completed;
for any plate, determining the size change of the plate at the actual splicing temperature according to the size of the plate at the reference splicing temperature, the linear expansion coefficient of the plate and the change of the actual splicing temperature and the reference splicing temperature, and obtaining the simulated size change of the plate;
determining the coordinate variation of the end part of the plate at the actual splicing temperature according to the simulated size variation of the plate, and obtaining the simulated coordinate of the end part of the plate at the actual splicing temperature according to the coordinate variation of the end part of the plate at the actual splicing temperature and the coordinate of the end part of the plate at the reference splicing temperature; the simulation coordinates of the end parts of the plates are used for guiding the positions of the end parts of the plates when the plates are spliced, so that the end parts of the plates are accurately spliced with the starting point of the next plate;
establishing a finite element model of two adjacent small-section steel box girders in a welding state, and carrying out finite element analysis according to an actual welding procedure to determine a top crack variable quantity and a bottom crack variable quantity between the two small-section steel box girders so as to obtain a simulated top crack variable quantity and a simulated bottom crack variable quantity between the two small-section steel box girders;
determining the difference value of the simulated top crack variable quantity and the simulated bottom crack variable quantity according to the simulated top crack variable quantity and the simulated bottom crack variable quantity, and obtaining a simulated crack variable quantity difference value;
correcting the sizes of the top plates of the contact ends of the two small-section steel box girders according to the simulated crack variation difference value to obtain the respective simulated top plate sizes of the two small-section steel box girders; the simulated top plate size of the small-section steel box girder is used for guiding the cutting of the small-section steel box girder, so that the length of the top plate in the small-section steel box girder after the actual welding is the same as the length of the bottom plate.
2. The deformation error control method according to claim 1, wherein the simulated longitudinal variation of each point in the transverse direction of the top sheet is determined using the following formula:
wherein f (x) is the simulated longitudinal variation distribution of each point in the transverse direction of the top plate, x is any point in the transverse direction of the top plate, a is the transverse interval of the U-shaped rib, A 0 、A 1 、A 2 、A 3 、B 0 、B 1 、B 2 、B 3 、C 0 、C 1 、C 2 、C 3 Fitting coefficients; and the central line of the U-shaped rib is a starting point 0, and the longitudinal variation is symmetrically distributed along the central line of the U-shaped rib.
3. The deformation error control method according to claim 1, wherein determining the longitudinal dimension of the top sheet and the longitudinal dimension of the bottom sheet according to the simulated longitudinal variation of the lateral points of the top sheet in the U-rib welding state and the simulated longitudinal variation of the lateral points of the bottom sheet in the U-rib welding state, and obtaining the simulated longitudinal dimension of the top sheet and the simulated longitudinal dimension of the bottom sheet comprises:
if the simulated longitudinal variation of each transverse point of the top plate in the U-shaped rib welding state is z, shortening the longitudinal dimension of the top plate by z before U-shaped rib welding is carried out on the top plate, so as to obtain the simulated longitudinal dimension of the top plate;
if the simulated longitudinal variation of each transverse point of the top plate in the U-shaped rib welding state is-z, extending the longitudinal dimension of the top plate by z before U-shaped rib welding is carried out on the top plate, so as to obtain the simulated longitudinal dimension of the top plate;
if the bottom plate is in a U-shaped rib welding stateThe simulated longitudinal variation of each point in the transverse direction of the material is z 1 The longitudinal dimension of the bottom plate is shortened by z before U-shaped rib welding is carried out on the bottom plate 1 Obtaining the simulated longitudinal dimension of the bottom plate;
if the simulated longitudinal variation of each transverse point of the bottom plate is-z 1 in the U-shaped rib welding state, the longitudinal dimension of the bottom plate is prolonged by z before the U-shaped rib welding is carried out on the bottom plate 1 The simulated longitudinal dimension of the bottom sheet is obtained.
4. The deformation error control method according to claim 1, wherein the dimensional change amount of the sheet material at the actual splicing temperature is determined according to the following formula:
Δl＝αΔTl
wherein Deltal is the size variation of the plate at the actual splicing temperature, alpha is the linear expansion coefficient of the plate, deltaT is the temperature variation of the reference splicing temperature and the actual splicing temperature, and l is the size of the plate at the reference splicing temperature.
5. The deformation error control method according to claim 1, wherein the amount of change in coordinates of the sheet material end at the actual splicing temperature is determined according to the following equation:
Δx＝Δlcosβ
Δy＝Δlsinβ
wherein Δx is the x-axis coordinate variation of the end of the plate at the actual splicing temperature, Δy is the y-axis coordinate variation of the end of the plate at the actual splicing temperature, Δl is the size variation of the plate at the actual splicing temperature, and β is the placement angle of the plate.
6. The deformation error control method according to claim 1, wherein the gap variation difference is determined according to the following equation:
δ＝δ top -δ bottom
wherein delta top To simulate a roof crackChange amount, delta bottom To simulate the bottom gap variation, δ is the gap variation difference.
7. The deformation error control method according to claim 6, wherein the correcting the sizes of the top plates of the contact ends of the two small-section steel box girders according to the simulated gap variation difference value to obtain the respective simulated top plate sizes of the two small-section steel box girders specifically comprises:
for any small-section steel box girder, shortening the size of the top plate at the contact end of the small-section steel box girder and the other small-section steel box girder by delta to obtain the respective simulated top plate size of the two small-section steel box girders.
8. The deformation error control method according to claim 6, wherein the correcting the sizes of the top plates of the contact ends of the two small-section steel box girders according to the simulated gap variation difference value to obtain the respective simulated top plate sizes of the two small-section steel box girders specifically comprises:
and respectively shortening the size of the top plate at the contact end of the two small-section steel box girders by delta/2 to obtain the respective simulated top plate size of the two small-section steel box girders.
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