CN115479962B - Method for rapidly and accurately calculating residual stress of inner part and inner surface of welded joint - Google Patents
Method for rapidly and accurately calculating residual stress of inner part and inner surface of welded joint Download PDFInfo
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Abstract
The invention discloses a method for rapidly and accurately calculating residual stress of the inner part and the inner surface of a welding joint, which completes the test of the whole residual stress of the welding joint by applying a combined test method of the residual stress, and establishing an actual distribution model of the residual stress of the welding joint along the thickness direction, and determining the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface. During field test, according to the established actual distribution model of the residual stress of the welded joint along the thickness direction, the quantitative test of the residual stress of the outer surface of the welded joint of the in-service equipment is carried out by an X-ray diffraction method, so that the residual stress of the inner part and the inner surface of the welded joint is rapidly and accurately calculated.
Description
Technical Field
The invention relates to the technical field of residual stress measurement, in particular to a method for rapidly and accurately calculating residual stress of the inner part and the inner surface of a welding joint.
Background
In the development of the modern industry, a welding process has become an integral part of the modern industry, and many important industrial equipment devices adopt welding structures, such as in-service pipelines, large storage tanks, pressure vessels and the like which are connected in a welding mode. It is worth noting that the welding joint is easy to generate defects such as cracks, inclusions, holes and the like due to non-uniformity of tissues and components, and meanwhile, larger welding residual stress exists, so that the welding joint becomes the weakest link of the equipment in use. Ensuring safe use of the welded joint is a highly desirable problem.
Disclosure of Invention
Aiming at the defects and the shortages existing in the prior art, the test and the research on the residual stress of the welded joint find that: quantitative relation exists between the residual stress on the outer surface of the welded joint and the residual stress on the inner surface and the internal residual stress, but the specific proportional relation is related to factors such as welding process, thickness, groove form and the like. And for the field test of the residual stress of the welding joint of the in-service equipment, the internal and internal surface residual stress of the welding joint can be rapidly and accurately calculated according to the external surface residual stress tested by a nondestructive testing method by establishing an actual distribution model of the residual stress of the welding joint along the thickness direction under the condition that the normal use of the equipment is not affected, so that the quantification of the whole residual stress of the welding joint is realized, the safe use of the equipment is favorably ensured, and the technical support is provided for more accurate equipment safety evaluation.
The invention provides a method for rapidly and accurately calculating residual stress of the inner part and the inner surface of a welding joint. The testing process specifically comprises the steps of using a residual stress combined testing method, firstly adopting an X-ray diffraction method to test the residual stress of the inner surface and the outer surface of the welding joint, then adopting a contour method to test the residual stress of the welding joint along the thickness direction, completing the test calculation of the whole residual stress of the welding joint, establishing an actual distribution model of the residual stress of the welding joint along the thickness direction, and determining the quantitative relation of the residual stress of the inner surface and the outer surface and the quantitative relation of the residual stress of the inner surface and the residual stress of the outer surface.
During field test, the quantitative test of the residual stress on the outer surface of the welding joint of the in-service equipment can be realized by an X-ray diffraction method according to the established actual distribution model of the residual stress of the welding joint along the thickness direction under the condition that the normal use condition of the in-service equipment is not affected, so that the residual stress inside and on the inner surface of the welding joint can be rapidly and accurately calculated.
According to the invention, through rapid and accurate calculation of residual stress in the welding joint and on the inner surface, the safety evaluation work of the welding joint of the in-service equipment can be conveniently, efficiently and rapidly carried out.
The method completes the test of the whole residual stress of the welding joint, establishes an actual distribution model of the residual stress of the welding joint along the thickness direction, and determines the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface. During field test, according to the established actual distribution model of the residual stress of the welded joint along the thickness direction, the quantitative test of the residual stress of the outer surface of the welded joint of the in-service equipment is carried out by an X-ray diffraction method, so that the residual stress of the inner part and the inner surface of the welded joint is rapidly and accurately calculated.
The method for rapidly and accurately calculating the residual stress of the inner part and the inner surface of the welding joint can rapidly and accurately finish the calculation of the whole residual stress of the welding joint of the in-service equipment by a nondestructive testing method under the condition that the normal use of the in-service equipment is not affected in the field testing process. The invention can obtain accurate overall residual stress distribution result of the welding joint under the conditions of no damage, convenience and less equipment investment, and has important significance for accurately evaluating the performance of the welding joint.
In order to achieve the above purpose, the invention adopts the following technical scheme:
a method for rapidly and accurately calculating residual stress of the inner part and the inner surface of a welded joint is characterized by comprising the following steps: firstly, testing the residual stress of the inner surface and the outer surface of a welded joint by adopting an X-ray diffraction method, then testing the residual stress of the inner part of the welded joint along the thickness direction by adopting a contour method, completing the test calculation of the whole residual stress of the welded joint, and establishing an actual distribution model of the residual stress of the welded joint along the thickness direction so as to determine the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface and the quantitative relation between the residual stress of the inner part and the residual stress of the outer surface;
And in the field test, according to the established actual distribution model of the residual stress of the welding joint along the thickness direction, quantitatively testing the residual stress of the outer surface of the welding joint of the in-service equipment by an X-ray diffraction method, and calculating the residual stress of the inner part and the inner surface of the welding joint.
Further, the residual stress of the inner surface and the outer surface of the welded joint is quantitatively tested in a nondestructive way by using an X-ray diffraction method, and the method specifically comprises the following steps:
when the residual stress on the surface of the test piece is tested by adopting an X-ray diffraction method, the test position is preprocessed: firstly polishing the surface by adopting a mechanical polishing mode, carrying out electrolytic polishing after mechanical polishing, and using an electrolytic polishing instrument to eliminate sample surface layer distortion tissues caused by mechanical processing;
After the pretreatment work and the equipment debugging work of the test are completed, testing residual stresses to be tested in different directions of the marked test points by using an X-ray stress analyzer, and quantitatively correcting the testing results of the X-ray stress analyzer.
Further, the contour method is used for testing the internal residual stress of the welded joint, and specifically comprises the following steps:
Firstly, symmetrically cutting a test piece along a surface to be tested by using a slow wire cutting technology in an electric spark cutting process; collecting profile displacement data of the cutting surface by using a three-coordinate measuring instrument; the collected data are subjected to processing including averaging processing, abnormal point screening and contour curve fitting;
After the profile data is processed, a corresponding geometric model is established in finite element software by using a numerical simulation method, the processed profile data is used as a self-defined displacement boundary condition to be arranged in the geometric model, and the Poisson ratio and the elastic modulus of physical parameters of the material are determined; and (5) carrying out stress reconstruction calculation through finite element software to obtain the distribution of residual stress in the welded joint vertical to the cutting surface.
Further, an actual distribution model of the residual stress of the welded joint along the thickness direction is established, and the method specifically comprises the following steps:
Correcting the near-surface internal residual stress data tested by the contour method by using the surface residual stress data tested by the X-ray diffraction method; after the correction is completed, data fitting is carried out through a function curve, so that an actual distribution model of the residual stress of the welding joint along the thickness direction is established, and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface are determined.
Further, based on the established actual distribution model of the residual stress of the welded joint in the thickness direction; in the actual use process, the X-ray diffraction method is adopted to quantitatively test the residual stress of the outer surface of the welding joint of the in-service equipment, the test result is quantitatively corrected, and then the residual stress of the inner surface and the inner surface of the welding joint is rapidly and accurately calculated according to the established actual distribution model of the residual stress of the welding joint along the thickness direction.
Compared with the prior art, the method and the device can realize accurate quantitative test of the whole residual stress of the welding joint by adopting the combined test method of the X-ray diffraction method and the contour method.
According to the established actual distribution model of the residual stress of the welding joint along the thickness direction, the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface can be determined. During field test, quantitative test data of residual stress on the outer surface of the welding joint of the in-service equipment can be obtained through an X-ray diffraction method under the condition that normal use of the in-service equipment is not affected, and the residual stress inside and on the inner surface of the welding joint can be rapidly and accurately calculated according to the established distribution model of the residual stress of the welding joint along the thickness direction.
Drawings
FIG. 1 is a flow chart of a method for rapidly and accurately estimating residual stress in a welded joint and on the inner surface according to an embodiment of the invention;
FIG. 2 is a schematic diagram of the residual stress on the outer surface of a welded joint according to an embodiment of the present invention;
FIG. 3 is a schematic illustration of the residual stress in the thickness direction of a welded joint tested by the contour method according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a finite element software stress reconstruction calculation according to an embodiment of the present invention;
FIG. 5 is a schematic view of a practical distribution model of residual stress of a welded joint along the thickness direction (residual stress perpendicular to the weld line direction) according to an embodiment of the present invention;
Fig. 6 is a schematic view of a practical distribution model of the residual stress of the welded joint according to the embodiment of the present invention (residual stress in the direction parallel to the weld joint) in the thickness direction.
Detailed Description
In order to make the features and advantages of the present patent more comprehensible, embodiments accompanied with figures are described in detail below:
It should be noted that the following detailed description is illustrative and is intended to provide further explanation of the application. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present application. As used herein, the singular is also intended to include the plural unless the context clearly indicates otherwise, and furthermore, it is to be understood that the terms "comprises" and/or "comprising" when used in this specification are taken to specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof.
The invention aims to realize rapid and accurate calculation of residual stress in the inner part and the inner surface of the welding joint of the in-service equipment, complete quantification of the whole residual stress of the welding joint and provide technical support for more accurate equipment safety evaluation. The embodiment provides a method for rapidly and accurately calculating residual stress of the inner surface and the inner surface of a welding joint, an actual distribution model of the residual stress of the welding joint along the thickness direction is established, and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface are determined. During field test, the quantitative test of the residual stress on the outer surface of the welding joint of the in-service equipment can be realized according to the established actual distribution model of the residual stress of the welding joint along the thickness direction under the condition that the normal use condition of the in-service equipment is not affected, and the residual stress of the inner part and the inner surface of the welding joint can be rapidly and accurately calculated through an X-ray diffraction method.
The scheme adopted specifically comprises the following steps:
(1) Nondestructive quantitative testing of residual stress on inner surface and outer surface of welded joint by using X-ray diffraction method
When the residual stress on the surface of the test piece is tested by adopting an X-ray diffraction method, the test position is pretreated. The surface may be polished by mechanical grinding, but this creates a machining residual compressive stress on the surface to a depth of a few hundred microns. It is therefore necessary to carry out electropolishing after mechanical polishing, and to use an electropolishing instrument to eliminate surface distortion tissue of the specimen resulting from the mechanical processing, to ensure accuracy of subsequent testing.
After the pretreatment work and the equipment debugging work of the test are completed, the X-ray stress analyzer is used for testing the residual stress to be tested in different directions of the marked test points. The quantitative test results of the X-ray diffraction method are error due to the differences of the weld metal, the heat affected zone and the parent metal in composition and structure. Therefore, the test result of the X-ray stress analyzer needs to be quantitatively corrected, and the accuracy of the test result is ensured.
(2) Contour method for testing residual stress in welded joint
Firstly, a test piece is symmetrically cut along a surface to be measured by using a slow wire cutting technology in an electric spark cutting process. And collecting the profile displacement data of the cutting surface by using a three-coordinate measuring instrument. To ensure accuracy of the contour data, a series of operations such as averaging, outlier screening, and contour curve fitting are required for the data.
After the contour data is processed, a corresponding geometric model is established in finite element software by using a numerical simulation method, the processed contour data is set in the geometric model as a self-defined displacement boundary condition, and the physical property parameters Poisson ratio and elastic modulus of the material are determined. And (5) carrying out stress reconstruction calculation through finite element software to obtain the distribution of residual stress in the welded joint vertical to the cutting surface.
(3) Establishing an actual distribution model of residual stress of the welding joint along the thickness direction
Because the X-ray penetration capability is limited, the X-ray diffraction method can only accurately test the residual stress of the surface of the welding joint within the thickness range of tens of micrometers, so that the contour method is adopted to finish the test of the residual stress in the welding joint. However, due to the limitation of the cutting technology, the deformation generated by the near-surface area on the cutting surface is large, so that the test result of the near-surface residual stress of the contour method is inaccurate. The surface residual stress data tested by the X-ray diffraction method is used for correcting the near-surface internal residual stress data tested by the contour method. After the correction is completed, data fitting is carried out through a proper function curve, so that an actual distribution model of the residual stress of the welding joint along the thickness direction is established, and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface are determined.
(4) Calculating residual stress of the inside and the inner surface of the welded joint
In the field test, the X-ray diffraction method is a nondestructive testing method, the testing equipment is convenient to carry, the testing process is convenient and quick, and the testing result is accurate. Under the condition that normal use of the in-service equipment is not affected, the residual stress on the outer surface of the welded joint of the in-service equipment is quantitatively tested by adopting an X-ray diffraction method, and the test result is quantitatively corrected. According to the established actual distribution model of the residual stress of the welding joint along the thickness direction, the residual stress of the inner part and the inner surface of the welding joint can be rapidly and accurately calculated.
Taking a V-groove welded joint as an example, the present embodiment further describes the scheme with reference to the example:
The flow chart of the method is shown in figure 1. And quantitatively testing the whole residual stress of the welding joint by using the combined testing method of the X-ray diffraction method and the contour method. The method comprises the following steps:
(1) After the test piece surface was pretreated, the residual stress of the welded joint surface was tested using an X-ray stress analyzer, as shown in fig. 2. And the deviation of test data caused by the non-uniform structure of weld metal, a heat affected zone and a parent metal zone is corrected, so that the accuracy of a test result is ensured.
(2) As shown in fig. 3, the residual stress in the welded joint is tested by using a contour method, the surface to be measured is symmetrically cut by a slow wire cutting machine, and then contour displacement data of the cut surface is measured by using a three-coordinate measuring instrument.
(3) As shown in fig. 4, the obtained profile data are subjected to series of operations such as averaging, abnormal point screening, profile curve fitting and the like, then a corresponding geometric model is established in finite element software by using a numerical simulation method, the processed profile data are set in the geometric model as self-defined displacement boundary conditions, the poisson ratio and the elastic modulus of physical parameters of the material are determined, and the internal residual stress distribution of the welded joint vertical to the cutting surface is obtained through stress reconstruction calculation.
(4) As shown in fig. 5 and 6, the surface residual stress data tested by the X-ray diffraction method is used for correcting the near-surface internal residual stress data tested by the contour method, a proper function curve is selected for data fitting, an actual distribution model of the residual stress of the welded joint along the thickness direction is established, and the quantitative relation between the internal surface residual stress and the external surface residual stress and the quantitative relation between the internal residual stress and the external surface residual stress are determined.
(5) During field test, the quantitative test of the residual stress on the outer surface of the welding joint of the in-service equipment can be realized by an X-ray diffraction method according to the established actual distribution model of the residual stress of the welding joint along the thickness direction under the condition that the normal use condition of the in-service equipment is not affected, so that the residual stress of the inner part and the inner surface of the welding joint can be rapidly and accurately calculated.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the invention in any way, and any person skilled in the art may make modifications or alterations to the disclosed technical content to the equivalent embodiments. However, any simple modification, equivalent variation and variation of the above embodiments according to the technical substance of the present invention still fall within the protection scope of the technical solution of the present invention.
The present invention is not limited to the above-mentioned best mode, any person can obtain other methods of various forms of fast and accurately calculating the residual stress of the inner and outer surfaces of the welding joint under the teaching of the present invention, and all equivalent changes and modifications made according to the scope of the present invention should be covered by the present invention.
Claims (1)
1. A method for rapidly and accurately calculating residual stress of the inner part and the inner surface of a welded joint is characterized by comprising the following steps: firstly, testing the residual stress of the inner surface and the outer surface of a welded joint by adopting an X-ray diffraction method, then testing the residual stress of the inner part of the welded joint along the thickness direction by adopting a contour method, completing the test calculation of the whole residual stress of the welded joint, and establishing an actual distribution model of the residual stress of the welded joint along the thickness direction so as to determine the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface and the quantitative relation between the residual stress of the inner part and the residual stress of the outer surface;
during field test, according to an established actual distribution model of the residual stress of the welding joint along the thickness direction, quantitatively testing the residual stress of the outer surface of the welding joint of in-service equipment by an X-ray diffraction method, and calculating the residual stress of the inner part and the inner surface of the welding joint;
The method for nondestructive quantitative testing of residual stress on the inner surface and the outer surface of the welded joint by using an X-ray diffraction method specifically comprises the following steps:
when the residual stress on the surface of the test piece is tested by adopting an X-ray diffraction method, the test position is preprocessed: firstly polishing the surface by adopting a mechanical polishing mode, carrying out electrolytic polishing after mechanical polishing, and using an electrolytic polishing instrument to eliminate sample surface layer distortion tissues caused by mechanical processing;
After the pretreatment work and the equipment debugging work of the test are finished, testing residual stresses to be tested in different directions of the marked test points by using an X-ray stress analyzer, and quantitatively correcting the test results of the X-ray stress analyzer;
The contour method for testing the residual stress in the welded joint specifically comprises the following steps:
Firstly, symmetrically cutting a test piece along a surface to be tested by using a slow wire cutting technology in an electric spark cutting process; collecting profile displacement data of the cutting surface by using a three-coordinate measuring instrument; the collected data are subjected to processing including averaging processing, abnormal point screening and contour curve fitting;
After the profile data is processed, a corresponding geometric model is established in finite element software by using a numerical simulation method, the processed profile data is used as a self-defined displacement boundary condition to be arranged in the geometric model, and the Poisson ratio and the elastic modulus of physical parameters of the material are determined; carrying out stress reconstruction calculation through finite element software to obtain the distribution of residual stress in the welded joint vertical to the cutting surface;
the method for establishing the actual distribution model of the residual stress of the welding joint along the thickness direction specifically comprises the following steps:
Correcting the near-surface internal residual stress data tested by the contour method by using the surface residual stress data tested by the X-ray diffraction method; after correction is completed, data fitting is carried out through a function curve, so that an actual distribution model of the residual stress of the welding joint along the thickness direction is established, and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface are determined;
Based on the established actual distribution model of the residual stress of the welding joint along the thickness direction; in the actual use process, the X-ray diffraction method is adopted to quantitatively test the residual stress of the outer surface of the welding joint of the in-service equipment, the test result is quantitatively corrected, and then the residual stress of the inner surface and the inner surface of the welding joint is rapidly and accurately calculated according to the established actual distribution model of the residual stress of the welding joint along the thickness direction.
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|---|---|---|---|---|
| CN103364336A (en) * | 2013-07-15 | 2013-10-23 | 江苏科技大学 | Method for testing full view of inner bidirectional residual stress of circumferential welding line |
| CN108491652A (en) * | 2018-03-29 | 2018-09-04 | 中国计量大学 | A kind of method for measuring welding residual stress based on ABAQUS |
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