CN116467806A - Method and system for calculating welding value of butt annular weld - Google Patents
Method and system for calculating welding value of butt annular weld Download PDFInfo
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Abstract
The invention provides a calculation method and a calculation system for welding values of butt-joint girth welds, wherein the method comprises the following steps: dividing grids for a pre-established butt annular welding model, and setting material characteristics and welding paths; setting corresponding initial conditions, boundary conditions and a heat source model in the butt annular welding model; and defining a target working condition, and determining a temperature field and a stress field according to the butt joint annular welding model. The simulation calculation of the welding value of the butt-joint annular welding seam can be realized, the temperature change and the post-welding residual stress in the welding process can be determined, the production efficiency can be effectively improved, and the welding quality can be ensured.
Description
Technical Field
The invention relates to the technical field of welding, in particular to a butt-joint annular welding seam welding numerical value calculation method and system.
Background
The arm support is a main stress structural member of the crawler crane, and determines the stability and safety of the whole crawler crane. Because the materials, the shapes and the heated areas of the two sides are different, a large number of welding cracks appear in the actual welding production process. Therefore, on the basis of improving the toughness of the welded joint and preventing welding cracks while ensuring the high strength of the boom, the research on the weldability and the welding process of the boom main chord and the joint is particularly necessary.
Residual stress exists in the production process, so that welding cracks are easy to generate in or after the welding process. The welding temperature field is difficult to detect due to the fact that the transient performance, the locality, the heat source movement, the molten pool liquid metal fierce movement and the like of the heat process in the welding process, the temperature field in the welding process cannot be monitored, the welding quality is unstable, the welding result is high accidentally, in order to ensure the welding quality of the dissimilar steel butt-joint annular welding seam, the traditional method relies on manual experience, a large number of workpiece tests are adopted to determine a welding scheme, and the method is high in cost, low in efficiency and large in workload.
Therefore, how to provide a calculation method and a system for the welding value of the butt annular welding seam, to realize the simulation calculation of the welding value of the butt annular welding seam, to determine the temperature change and the residual stress after welding in the welding process, to effectively improve the production efficiency and to ensure the welding quality.
Disclosure of Invention
Aiming at the defects in the prior art, the embodiment of the invention provides a butt annular welding seam welding numerical value calculation method and a butt annular welding seam welding numerical value calculation system.
The invention provides a calculation method of a butt-joint annular welding seam welding numerical value, which comprises the following steps:
dividing grids for a pre-established butt annular welding model, and setting material characteristics and welding paths;
setting corresponding initial conditions, boundary conditions and a heat source model in the butt annular welding model;
and defining a target working condition, and determining a temperature field and a stress field according to the butt joint annular welding model.
According to the butt annular welding numerical calculation method provided by the invention, before the step of meshing the pre-established butt annular welding model and setting the material characteristics and the welding path, the method further comprises the following steps:
respectively establishing a three-dimensional geometric model based on the physical structures of the first welding piece, the second welding piece and the welding seam;
and determining a butt annular welding model based on the three-dimensional geometric model.
According to the butt annular welding numerical calculation method provided by the invention, a pre-established butt annular welding model is meshed, and material characteristics and welding paths are set, and the method specifically comprises the following steps:
dividing grids of a pre-established butt joint annular welding model according to preset grid division rules;
and setting material characteristics and establishing a welding path based on the material thermophysical properties and mechanical properties of the butt annular welding model.
According to the calculation method of the welding value of the butt annular welding seam, which is provided by the invention, the pre-established butt annular welding model is divided into grids according to a preset grid division rule, and the calculation method specifically comprises the following steps:
determining a model minimum symmetry unit based on the geometric symmetry of the butt-joint annular welding model;
according to a preset grid division rule, grid division is performed on the minimum symmetric unit of the model; wherein, the grid cells close to the weld joint area are densely divided, and the grid cells far away from the weld joint area are sparsely divided;
and determining a butted annular welding model after grid division based on the minimum symmetric unit of the model after grid division.
According to the butt annular welding seam welding numerical calculation method provided by the invention, initial conditions comprise: initial temperature and ambient temperature; the boundary condition is a displacement constraint condition; the heat source model is a double-ellipsoid thermal element model.
According to the calculation method for the welding value of the butt annular weld, provided by the invention, the displacement constraint condition is that the weldment does not displace in the welding process.
According to the butt annular welding numerical calculation method provided by the invention, a target working condition is defined, and a temperature field and a stress field are determined according to a butt annular welding model, and the method specifically comprises the following steps:
defining a target working condition, and determining a welding step and a cooling step;
based on the welding step and the cooling step, a temperature field and a stress field are determined according to the butt annular welding model.
The invention also provides a butt annular weld welding numerical calculation system, which comprises: a model setting unit, a parameter setting unit and a numerical value calculating unit;
the model setting unit is used for meshing a pre-established butt annular welding model and setting material characteristics and welding paths;
the parameter setting unit is used for setting corresponding initial conditions, boundary conditions and heat source models in the butt annular welding model;
and the numerical calculation unit is used for defining a target working condition and determining a temperature field and a stress field according to the butt joint annular welding model.
The invention also provides an electronic device comprising a memory, a processor and a computer program stored on the memory and capable of running on the processor, wherein the processor executes the program to realize the steps of any one of the butt annular welding numerical calculation methods.
The present invention also provides a non-transitory computer readable storage medium having stored thereon a computer program which, when executed by a processor, performs the steps of any of the butt girth weld numerical calculation methods described above.
According to the butt-joint annular welding seam welding numerical value calculation method and system, the established butt-joint annular welding model is used for simulating a welding process, welding numerical values of the butt-joint annular welding seam are calculated, a temperature field and a stress field are determined, and temperature change in the welding process and distribution of residual stress after welding are analyzed. The simulation calculation is carried out before the physical welding, so that the relation between the welding process and the welding deformation can be clarified in advance, the welding process is optimized and regulated in time, the production efficiency is effectively improved, and the welding quality is ensured.
Drawings
In order to more clearly illustrate the invention or the technical solutions of the prior art, the following description will briefly explain the drawings used in the embodiments or the description of the prior art, and it is obvious that the drawings in the following description are some embodiments of the invention, and other drawings can be obtained according to the drawings without inventive effort for a person skilled in the art.
FIG. 1 is a flow chart of a calculation method of a welding value of a butt annular welding seam;
FIG. 2 is a schematic diagram of a mesh of a butt annular welding model provided by the invention;
FIG. 3 is a schematic view of a weld path provided by the present invention;
FIG. 4 is a cloud image of the temperature field at the end of the first weld provided by the present invention;
FIG. 5 is a temperature field cloud chart of cooling 40s after the welding of the first layer of welding seam is finished;
FIG. 6 is a cloud image of the temperature field at the end of the second weld provided by the present invention;
FIG. 7 is a temperature field cloud chart of cooling 40s after the second layer of welding seam is welded;
FIG. 8 is a cloud image of the temperature field at the end of the third weld provided by the present invention;
FIG. 9 is a cloud image of the temperature field at the end of the fourth weld provided by the present invention;
FIG. 10 is a temperature field cloud chart of cooling 40s after the third layer of weld joint provided by the invention is welded;
FIG. 11 is a cloud image of the temperature field at the end of the fifth weld provided by the present invention;
FIG. 12 is a cloud image of the temperature field at the end of the sixth weld provided by the present invention;
FIG. 13 is a cloud image of the temperature field at the end of the seventh weld provided by the present invention;
FIG. 14 is a temperature field cloud chart of cooling 600s after all welds provided by the present invention are welded;
FIG. 15 is a cloud chart of a temperature field for cooling 6000s after all welds provided by the invention are welded;
FIG. 16 is a cloud of stress fields provided by the present invention;
FIG. 17 is a schematic diagram of a butt weld numerical calculation system according to the present invention;
fig. 18 is a schematic diagram of an entity structure of an electronic device according to the present invention.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings, and it is apparent that the described embodiments are some embodiments of the present invention, 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.
Fig. 1 is a flowchart of a method for calculating a welding value of a butt annular welding seam according to the present invention, and as shown in fig. 1, the method for calculating a welding value of a butt annular welding seam according to the present invention includes:
step S1, meshing a pre-established butt annular welding model, and setting material characteristics and welding paths;
step S2, setting corresponding initial conditions, boundary conditions and a heat source model in the butt annular welding model;
and S3, defining a target working condition, and determining a temperature field and a stress field according to the butt joint annular welding model.
Specifically, the invention adopts finite element software to pre-establish a physical model of dissimilar steel butt-joint annular welding seam welding, namely a butt-joint annular welding model. It will be appreciated that the butt annular welding model is established based on the structure used for welding in the actual application of the present invention, and can be adjusted according to the actual requirements, and the present invention is not limited thereto.
In step S1, a pre-established butt-joint annular welding model is imported into finite element preprocessing software (such as HyperMesh software), and the three-dimensional finite element model is subjected to mesh division, and material characteristics and welding paths are set.
It will be appreciated that the material characteristics of the model are set according to the physical properties of the materials used in actual welding, and the welding path is set according to the actual requirements, which is not limited by the present invention.
In step S2, corresponding initial conditions, boundary conditions and heat source models are set in the butt annular welding model.
It will be appreciated that the initial conditions, boundary conditions and heat source models of the model may be set according to the requirements of the actual weld, as the invention is not limited in this regard.
In step S3, a target working condition is defined, the target working condition is an operation performed by welding in practical application, and based on a butt joint annular welding model, a welding process under the target working condition is simulated to obtain a relevant numerical result of a temperature field and a stress field.
The distribution conditions of the temperature field and the residual stress after welding are analyzed to determine the stress distribution range and the stress distribution size, so that whether welding deformation exists under the target working condition can be determined, the actual operation on site is guided, the traditional test is replaced by a simulation calculation method, and the defects of the traditional test can be effectively overcome.
According to the calculation method for the welding value of the butt annular welding seam, the established butt annular welding model is used for simulating the welding process, the welding value of the butt annular welding seam is calculated, the temperature field and the stress field are determined, and the temperature change in the welding process and the distribution condition of residual stress after welding are analyzed. The simulation calculation is carried out before the physical welding, so that the relation between the welding process and the welding deformation can be clarified in advance, the welding process is optimized and regulated in time, the production efficiency is effectively improved, and the welding quality is ensured.
Optionally, according to the calculation method for welding values of the butt annular welding seam provided by the invention, before the step of meshing the pre-established butt annular welding model and setting the material characteristics and the welding path, the calculation method further comprises the following steps:
respectively establishing a three-dimensional geometric model based on the physical structures of the first welding piece, the second welding piece and the welding seam;
and determining a butt annular welding model based on the three-dimensional geometric model.
Specifically, prior to the step of meshing the pre-established butt annular welding model to set the material characteristics and welding paths, a butt annular welding model also needs to be established.
Fig. 2 is a schematic diagram of mesh division of a butt annular welding model provided by the invention, as shown in fig. 2, from left to right in the figure, a first welding piece and a second welding piece are respectively a butt joint and a circular tube. Based on the physical structure of the butt joint, the round tube and the weld, three-dimensional geometric models are built according to the drawing by using three-dimensional software (such as UG (unigraphics), pro/E (Pro/Engineer) and the like). And based on the three-dimensional geometric model, the butt joint annular welding model is determined in a combined mode, and the model is imported into Hypermesh finite element software in a stp format for grid division.
It should be understood that the mesh division manner of the butt annular welding model shown in fig. 2 is merely a specific example for illustrating the present invention, and other structures may be adopted in addition to the above, which is not a limitation of the present invention.
According to the calculation method for the welding value of the butt annular welding seam, the established butt annular welding model is used for simulating the welding process, the welding value of the butt annular welding seam is calculated, the temperature field and the stress field are determined, and the temperature change in the welding process and the distribution condition of residual stress after welding are analyzed. The simulation calculation is carried out before the physical welding, so that the relation between the welding process and the welding deformation can be clarified in advance, the welding process is optimized and regulated in time, the production efficiency is effectively improved, and the welding quality is ensured.
Optionally, according to the calculation method for welding values of the butt annular welding seam provided by the invention, the pre-established butt annular welding model is meshed, and the material characteristics and the welding paths are set, which specifically comprises:
dividing grids of a pre-established butt joint annular welding model according to preset grid division rules;
and setting material characteristics and establishing a welding path based on the material thermophysical properties and mechanical properties of the butt annular welding model.
Specifically, taking the mesh schematic diagram of the butt-joint annular welding model shown in fig. 2 as an example, according to a preset mesh division rule, dividing the mesh, and the butt-joint annular welding model after mesh division is shown in fig. 2.
It can be understood that the specific size of the grid in the preset grid dividing rule and the dividing rule can be set according to actual requirements, and the invention is not limited to this.
After meshing, the thermophysical properties and mechanical properties of the joint, the round tube and the weld joint materials are determined, and in nonlinear finite element analysis software (such as MARC software), new material characteristics (different parameters are set for different materials in the model) including density, specific heat capacity, thermal expansion coefficient, heat conductivity coefficient, young's modulus, poisson's ratio, yield stress and the like are established.
The unit of material characteristics is unified, and the unit system in the material library is T-mm-s, so that the same unit system is required when the geometric model is built, the boundary condition is added and the initial condition is added. In addition, the material characteristic value cannot be zero, otherwise, the rigidity matrix is zero, and the operation cannot be performed.
FIG. 3 is a schematic diagram of a weld path provided by the present invention, as shown in FIG. 3, using the tool box function of the nonlinear finite element analysis software itself to establish the weld path. Firstly, a circular curve is established in software according to a geometric function, and a welding path is established through a welding path function of a tool box (each welding seam has two paths, one is a welding path and the other is a directional path).
According to the calculation method for the welding value of the butt annular welding seam, the established butt annular welding model is used for simulating the welding process, the welding value of the butt annular welding seam is calculated, the temperature field and the stress field are determined, and the temperature change in the welding process and the distribution condition of residual stress after welding are analyzed. The simulation calculation is carried out before the physical welding, so that the relation between the welding process and the welding deformation can be clarified in advance, the welding process is optimized and regulated in time, the production efficiency is effectively improved, and the welding quality is ensured.
Optionally, according to the calculation method for the welding value of the butt annular welding seam provided by the invention, for a pre-established butt annular welding model, according to a preset grid division rule, grid division is performed, and the method specifically comprises the following steps:
determining a model minimum symmetry unit based on the geometric symmetry of the butt-joint annular welding model;
according to a preset grid division rule, grid division is performed on the minimum symmetric unit of the model; wherein, the grid cells close to the weld joint area are densely divided, and the grid cells far away from the weld joint area are sparsely divided;
and determining a butted annular welding model after grid division based on the minimum symmetric unit of the model after grid division.
Specifically, taking the mesh division mode of the butt annular welding model shown in fig. 2 as an example, according to the geometric symmetry of the model, determining that the minimum symmetry unit of the model is a solid model of 1/4.
It will be appreciated that in the practice of the present invention, the smallest unit of symmetry of the model corresponds to the structure of the model. In addition, the special condition that the butt joint annular welding model has countless symmetry axes exists, and at the moment, the minimum symmetry unit of the model can select a symmetry unit which is convenient to calculate according to actual requirements.
According to a preset grid division rule, firstly dividing 1/4 of the grids of the solid model, wherein grid nodes are in one-to-one correspondence when dividing the grids, so that normal calculation success is ensured. The welding seam and the grids in the adjacent area are finely divided, the grid size of the welding seam is small at the position, away from the welding seam area, of increasing the grid size, the grid size away from the welding seam is large, and the calculation accuracy can be guaranteed and the calculation efficiency can be improved through sparse division.
And finally, dividing the 1/4 grid model into a whole model by using a mapping mode, and importing the grid model into nonlinear finite element analysis software in the format of inp.
According to the calculation method for the welding value of the butt annular welding seam, the established butt annular welding model is used for simulating the welding process, the welding value of the butt annular welding seam is calculated, the temperature field and the stress field are determined, and the temperature change in the welding process and the distribution condition of residual stress after welding are analyzed. The simulation calculation is carried out before the physical welding, so that the relation between the welding process and the welding deformation can be clarified in advance, the welding process is optimized and regulated in time, the production efficiency is effectively improved, and the welding quality is ensured.
Optionally, according to the butt annular welding seam welding numerical calculation method provided by the invention, initial conditions include: initial temperature and ambient temperature; the boundary condition is a displacement constraint condition; the heat source model is a double-ellipsoid thermal element model.
Specifically, setting initial conditions and boundary conditions of the butt annular welding model and selecting a proper heat source model comprises the following steps:
in a module of nonlinear finite element analysis software initial conditions, a thermal analysis, i.e. the initial temperature of the weld and the ambient temperature, is established.
In a module of boundary conditions of nonlinear finite element analysis software, displacement constraint is established, convection boundary conditions of a workpiece and an external environment are applied, and welding heat sources and heat source size parameters are set.
It will be appreciated that the initial conditions and boundary conditions may be set according to actual requirements, as the invention is not limited in this regard.
Selecting a double-ellipsoid heat source model based on the butt-joint annular weld joint, and correcting the heat source model, wherein the method comprises the following steps of: penetration c, width b, front end length a1, and rear end length a2.
The double-ellipsoid heat source model considers the difference of the temperature gradients of the front part and the rear part of the heat source model, and the double-ellipsoid heat source model is adopted to enable the simulation to be more accurate, closer to the actual situation and the calculation result to be closer to the actual situation.
According to the calculation method for the welding value of the butt annular welding seam, the established butt annular welding model is used for simulating the welding process, the welding value of the butt annular welding seam is calculated, the temperature field and the stress field are determined, and the temperature change in the welding process and the distribution condition of residual stress after welding are analyzed. The simulation calculation is carried out before the physical welding, so that the relation between the welding process and the welding deformation can be clarified in advance, the welding process is optimized and regulated in time, the production efficiency is effectively improved, and the welding quality is ensured.
Optionally, according to the calculation method for the welding value of the butt annular welding seam provided by the invention, the displacement constraint condition is that the welding piece does not displace in the welding process.
Specifically, when the constraint condition is applied, a displacement constraint boundary condition is applied to the welding piece, so that the welding piece does not displace during welding. The simulation conditions are consistent with the conditions in actual welding, and the accuracy of the simulation calculation result is ensured.
According to the calculation method for the welding value of the butt annular welding seam, the established butt annular welding model is used for simulating the welding process, the welding value of the butt annular welding seam is calculated, the temperature field and the stress field are determined, and the temperature change in the welding process and the distribution condition of residual stress after welding are analyzed. The simulation calculation is carried out before the physical welding, so that the relation between the welding process and the welding deformation can be clarified in advance, the welding process is optimized and regulated in time, the production efficiency is effectively improved, and the welding quality is ensured.
Optionally, according to the calculation method for the welding value of the butt annular welding seam provided by the invention, a target working condition is defined, and a temperature field and a stress field are determined according to the butt annular welding model, and the calculation method specifically comprises the following steps:
defining a target working condition, and determining a welding step and a cooling step;
based on the welding step and the cooling step, a temperature field and a stress field are determined according to the butt annular welding model.
Specifically, when performing simulation calculation, a target working condition needs to be defined, wherein the target working condition is the step required by simulating the actual welding process, and the welding step and the cooling step are determined.
Taking the butt annular welding model shown in fig. 2 as an example, defining a target working condition, and establishing 11 analysis steps, namely 7 welding steps and 4 cooling steps.
The first analysis step is step-1, and welding of a first welding line is carried out; a second analysis step-2, cooling the first layer; thirdly, performing step-3, namely performing welding of a second welding line; a fourth analysis step-4, cooling the second layer; fifth analysis step-5, welding the third welding line; a sixth analysis step-6, in which the fourth weld is welded; seventh analysis step-7, cooling the third layer; the eighth analysis step is step-8, and the fifth welding line is welded; the ninth analysis step is step-9, and the welding of a sixth welding line is carried out; the tenth analysis step is step-10, and the seventh welding line is welded; the eleventh analysis step is step-11, i.e., the cooling process after the entire welding process is completed.
It should be noted that the above target working conditions are only used as a specific example to illustrate the present invention, and in addition, different target working conditions may be set according to actual requirements, which is not limited by the present invention.
Based on the welding step and the cooling step, according to the butt joint annular welding model, submitting a solving task to solve, and calculating to obtain a temperature field and a stress field.
According to the calculation method for the welding value of the butt annular welding seam, the established butt annular welding model is used for simulating the welding process, the welding value of the butt annular welding seam is calculated, the temperature field and the stress field are determined, and the temperature change in the welding process and the distribution condition of residual stress after welding are analyzed. The simulation calculation is carried out before the physical welding, so that the relation between the welding process and the welding deformation can be clarified in advance, the welding process is optimized and regulated in time, the production efficiency is effectively improved, and the welding quality is ensured.
The method for calculating the welding numerical value of the butt-joint girth weld provided by the invention is explained by taking the specific steps of welding simulation calculation of the butt-joint girth weld of dissimilar high-strength steel as an example.
Taking a boom rotating rod of a crawler crane as an example, wherein the round pipe is BJ890, the size is 219mm multiplied by 300mm multiplied by 15mm, the joint is 20CrMnTi, welding wires of ER50-6 mm and phi 1.2mm are adopted as welding materials for priming, and welding wires of GM-120 mm and phi 1.2mm are adopted for filling and cover welding.
Wherein, the chemical compositions of the 20CrMnTi and the BJ890 are as follows (wt.%):
the welding wire T Union GM120 and welding wire ER50-6 had the following chemical compositions (wt.%) as shown in the Table:
the whole welding process is completed in 7 channels. The welding preheating temperature is 175 ℃, the interlayer temperature is controlled between 200 and 350 ℃ in the welding process, and the welding path is shown in figure 3.
The method is implemented according to the following steps:
and establishing a three-dimensional solid model of the joint, the circular tube and the welding seam according to the drawing size, wherein the solid model is divided into three parts, namely the joint, the circular tube and the welding seam, and the three parts are assembled into a complete solid model by utilizing an assembly module in UG software, and finally, the model is imported into Hypermesh software in a format of stp.
The three-dimensional model is imported into Hypermesh software, in order to improve the grid partitioning efficiency, the model imported into Hypermesh software is partitioned into 1/4 parts, a welding line part is partitioned firstly, then grids of a solid joint and a circular pipe part are partitioned, the grids of the welding line part correspond to grid nodes of the joint and circular pipe solid model one by one, and if the condition that the nodes do not correspond to each other, calculation errors occur, so that calculation operation is unsuccessful;
the minimum size of the welding seam at the welding seam is set to be 0.5mm, the grid size of the area close to the welding seam is 1.5mm, and the maximum size of the grid far away from the welding seam area is 4mm. After grid division, the model is divided into 9 parts, namely a joint, a round tube and 7 welding seams by using a software component function. And finally, importing the grid model into MARC software in the format of inp.
Determining material characteristics of dissimilar high-strength steel butt-joint girth weld welding and establishing a welding path;
in MARC software, the length unit of the model is set to be m, the characteristics of the new material are defined, and the thermal physical properties and physical properties of the joint, the round tube and the welding seam material are defined, including density, specific heat capacity, thermal expansion coefficient, heat conductivity coefficient, elastic modulus, poisson's ratio, yield strength and the like;
when adding material properties, the unit needs to be unified, and the unit system in the material library is T-mm-s, so that when building a geometric model, adding boundary conditions and initial conditions, the same unit system is required to be adopted. In addition, the value cannot be zero, otherwise, the rigidity matrix is zero, and the operation cannot be performed.
The MARC software is utilized to establish a welding path by utilizing the self-contained tool box function. The welding in this example was 7 passes, a circular curve was established using the geometric functions in the software, two curves for each weld, one for the weld path and one for the weld direction. A circular curve and establishes a welding path through the welding path function of the tool box.
Setting initial conditions and boundary conditions of a welding model and selecting a proper heat source model, in a module of the initial conditions of the MARC, establishing thermal analysis, namely initial temperature of a welding piece, ambient temperature, displacement constraint and facing flow, and setting convection coefficients of a workpiece and the outside to 40.
In this embodiment, the welding member is made of high-strength steel, and preheating is required before welding, and then the initial temperature is set to 175 ℃ and the ambient temperature is set to 20 ℃. And (3) applying displacement constraint boundary conditions to the welding parts, so that the welding parts do not displace during welding.
The heat source model selects a double-ellipsoid heat source model, and the welding heat source model of marc self-contained is adopted in the embodiment, namely a Goldart double-ellipsoid heat source model is shown in figure 2. Wherein the distribution form of the heat source is as follows:
(1) The first half ellipsoid heat source expression:
(2) The latter half ellipsoidal heat source expression:
wherein f 1 、f 2 Is the heat flux density distribution coefficient, and f 1 +f 2 =2, q is the heat input power, v is the welding speed, a 1 、a 2 And b and c are parameters defining the shape of the ellipsoid.
Wherein q=η·i·u, where η is the welding thermal efficiency; i is welding current, U is welding voltage; a, a 1 、a 2 The values of b, c are determined based on the size of the melt pool to be formed by the corrected heat source model.
In this embodiment, the heat source parameters: a, a 1 ＝0.008m、a 2 ＝0.012m、b＝0.006m、c＝0.006m、η＝0.7。
Technological parameters: the current I ranges from 270 to 300A, in this embodiment I is 290A, the voltage U ranges from 25 to 28V, and in this embodiment U is 27V; the welding speed was 7mm/s.
Establishing a solving task, submitting task solving and performing post-processing;
defining a target working condition, and establishing 11 analysis steps of the whole model, namely 7 welding steps and 4 cooling steps. The first analysis step is step-1, and welding of a first welding line is carried out; a second analysis step-2, wherein the cooling time of the first layer is 40s; thirdly, performing step-3, namely performing welding of a second welding line; a fourth analysis step-4, wherein the cooling time of the second layer is 40s; fifth analysis step-5, welding the third welding line; a sixth analysis step-6, in which the fourth weld is welded; seventh analysis step-7, cooling the third layer for 40s; the eighth analysis step is step-8, and the fifth welding line is welded; the ninth analysis step is step-9, and the welding of a sixth welding line is carried out; the tenth analysis step is step-10, and the seventh welding line is welded; the eleventh analysis step was step-11, i.e., the cooling process after the completion of the entire welding process, with a cooling time of 6000s.
And simulating and solving the welding process by using MARC (welding heat treatment assembly simulation software), submitting an analysis task, solving a temperature field and a stress field, and calculating the welding simulation temperature field and residual stress field results of each group. Before submitting the task, the task can be submitted and checked to see whether the parameter setting of the model is correct, so that the running efficiency is improved. And extracting the result to obtain the result of the welding temperature field and the stress field.
For the temperature field, fig. 4 is a temperature field cloud chart provided by the invention when the first welding seam is welded, and the central temperature of the heat source is 2217 ℃ when the first welding seam is welded;
FIG. 5 is a cloud image of a temperature field of 40s after welding of a first layer of welding seam, wherein the maximum temperature of the temperature field of 40s after welding of the first layer is 244.8 ℃;
FIG. 6 is a cloud chart of a temperature field at the end of the second weld joint welding, wherein the center temperature of a heat source is 2352 ℃ at the end of the second weld joint welding;
FIG. 7 is a cloud chart of a temperature field of 40s after the welding of the second layer of welding seam is finished, and the temperature field of 40s after the welding of the second layer of welding seam is finished, wherein the highest temperature is 282.1 ℃;
FIG. 8 is a cloud chart of a temperature field at the end of the third welding seam welding, wherein the center temperature of a heat source is 2311 ℃ at the end of the third welding seam welding;
FIG. 9 is a cloud chart of a temperature field at the end of welding a fourth weld joint, wherein the center temperature of a heat source is 2335 ℃ at the end of welding the fourth weld joint;
FIG. 10 is a cloud chart of a temperature field of 40s after welding of a third layer of welding seam, wherein the highest temperature of the temperature field of 40s after welding of the third layer of welding seam is 333.8 ℃;
FIG. 11 is a cloud chart of a temperature field at the end of welding a fifth weld joint, wherein the center temperature of a heat source is 2212 ℃ at the end of welding the fifth weld joint;
FIG. 12 is a cloud chart of a temperature field at the end of welding a sixth weld provided by the invention, wherein the central temperature of a heat source is 2218 ℃ at the end of welding the sixth weld;
FIG. 13 is a cloud chart of a temperature field at the end of welding a seventh weld joint, wherein the center temperature of a heat source is 2362 ℃ at the end of welding the seventh weld joint;
FIG. 14 is a temperature field cloud chart of cooling 600s after all welds are welded, and the highest temperature is 99.54 ℃.
FIG. 15 is a temperature field cloud chart of cooling 6000s after all welding seams are welded, wherein the maximum temperature is 26.48 ℃ after all welding seams are welded.
From the above figures, it can be seen that the temperature at the weld is highest, the 7 weld puddles are all around 2200-2400 ℃, and the temperature far from the weld zone gradually decreases.
For the stress field, a stress field cloud chart provided by the invention is shown in fig. 16, and fig. 16 is an equivalent residual stress field after 6000s cooling, wherein the residual stress of a welding line is mainly concentrated at the welding line and a heat affected zone, and the maximum residual stress appears at the welding line, and the size is 755.2Mpa. The weld near the tubular appendage is more stressed than near the joint.
According to the calculation method for the welding value of the butt-joint annular welding seam, the temperature field and the stress field in the welding process can be accurately calculated, and data analysis and comparison are carried out according to simulation results under different welding parameters, so that the better welding parameters and welding process are obtained. The invention combines finite element numerical simulation and data analysis, greatly improves the working efficiency, reduces the test cost, has the characteristic of simple and convenient operation, and ensures the accuracy requirement. It is to be understood that the above-described invention is merely illustrative of one specific example and is not to be construed as limiting the invention.
Fig. 17 is a schematic structural diagram of a calculation system for welding values of a butt annular welding seam according to the present invention, and as shown in fig. 17, the present invention also provides a calculation system for welding values of a butt annular welding seam, including: a model setting unit 171, a parameter setting unit 172, and a numerical value calculating unit 173;
a model setting unit 171 for meshing a pre-established butt annular welding model, setting material characteristics and welding paths;
a parameter setting unit 172 for setting corresponding initial conditions, boundary conditions, and heat source models in the butt annular welding model;
the numerical calculation unit 173 is configured to define a target working condition, and determine a temperature field and a stress field according to the butt annular welding model.
Specifically, the invention adopts finite element software to pre-establish a physical model of dissimilar steel butt-joint annular welding seam welding, namely a butt-joint annular welding model. It will be appreciated that the butt annular welding model is established based on the structure used for welding in the actual application of the present invention, and can be adjusted according to the actual requirements, and the present invention is not limited thereto.
The model setting unit 171 is configured to import a pre-established butt annular welding model into finite element preprocessing software (such as HyperMesh software), mesh the three-dimensional finite element model, and set material characteristics and welding paths.
It will be appreciated that the material characteristics of the model are set according to the physical properties of the materials used in actual welding, and the welding path is set according to the actual requirements, which is not limited by the present invention.
And a parameter setting unit 172 for setting corresponding initial conditions, boundary conditions, and heat source models in the butt annular welding model.
It will be appreciated that the initial conditions, boundary conditions and heat source models of the model may be set according to the requirements of the actual weld, as the invention is not limited in this regard.
The numerical calculation unit 173 is configured to define a target working condition, which is an operation performed by welding in practical application, and simulate a welding process under the target working condition based on a butt annular welding model, so as to obtain a relevant numerical result of a temperature field and a stress field.
The distribution conditions of the temperature field and the residual stress after welding are analyzed to determine the stress distribution range and the stress distribution size, so that whether welding deformation exists under the target working condition can be determined, the actual operation on site is guided, the traditional test is replaced by a simulation calculation method, and the defects of the traditional test can be effectively overcome.
According to the butt-joint annular welding seam welding numerical value calculation system, the welding process is simulated through the established butt-joint annular welding model, the welding numerical value of the butt-joint annular welding seam is calculated, the temperature field and the stress field are determined, and the temperature change in the welding process and the distribution condition of residual stress after welding are analyzed. The simulation calculation is carried out before the physical welding, so that the relation between the welding process and the welding deformation can be clarified in advance, the welding process is optimized and regulated in time, the production efficiency is effectively improved, and the welding quality is ensured.
It should be noted that, the calculation system for the welding value of the butt annular welding seam provided by the present invention is used for executing the calculation method for the welding value of the butt annular welding seam, and the specific implementation manner and the implementation manner of the method are consistent, and are not repeated here.
Fig. 18 is a schematic diagram of an entity structure of an electronic device according to the present invention, as shown in fig. 18, the electronic device may include:
a processor (processor) 181, a communication interface (Communications Interface) 182, a memory (memory) 183, and a communication bus 184, wherein the processor 181, the communication interface 182, and the memory 183 communicate with each other via the communication bus 184. Processor 181 may invoke logic instructions in memory 183 to perform a butt girth weld numerical calculation method comprising: dividing grids for a pre-established butt annular welding model, and setting material characteristics and welding paths; setting corresponding initial conditions, boundary conditions and a heat source model in the butt annular welding model; and defining a target working condition, and determining a temperature field and a stress field according to the butt joint annular welding model.
Further, the logic instructions in the memory 183 described above may be implemented in the form of software functional units and sold or used as a separate product, and may be stored in a computer readable storage medium. Based on this understanding, the technical solution of the present invention may be embodied essentially or in a part contributing to the prior art or in a part of the technical solution in the form of a software product stored in a storage medium, comprising several instructions for causing a computer device (which may be a personal computer, a server, a network device, etc.) to perform all or part of the steps of the method of the embodiments of the present invention. And the aforementioned storage medium includes:
a U-disk, a removable hard disk, a Read-Only Memory (ROM), a random access Memory (RAM, random Access Memory), a magnetic disk, or an optical disk, or other various media capable of storing program codes.
In another aspect, the present invention also provides a computer program product comprising a computer program stored on a non-transitory computer readable storage medium, the computer program comprising program instructions which, when executed by a computer, are capable of performing the butt weld numerical calculation method provided by the above methods, the method comprising: dividing grids for a pre-established butt annular welding model, and setting material characteristics and welding paths; setting corresponding initial conditions, boundary conditions and a heat source model in the butt annular welding model; and defining a target working condition, and determining a temperature field and a stress field according to the butt joint annular welding model.
In yet another aspect, the present invention also provides a non-transitory computer readable storage medium having stored thereon a computer program which, when executed by a processor, is implemented to perform the above-provided butt girth weld numerical calculation method, the method comprising: dividing grids for a pre-established butt annular welding model, and setting material characteristics and welding paths; setting corresponding initial conditions, boundary conditions and a heat source model in the butt annular welding model; and defining a target working condition, and determining a temperature field and a stress field according to the butt joint annular welding model.
The apparatus embodiments described above are merely illustrative, wherein elements illustrated as separate elements may or may not be physically separate, and elements shown as elements may or may not be physical elements, may be located in one place, or may be distributed over a plurality of network elements. Some or all of the modules may be selected according to actual needs to achieve the purpose of the solution of this embodiment. Those of ordinary skill in the art will understand and implement the present invention without undue burden.
From the above description of the embodiments, it will be apparent to those skilled in the art that the embodiments may be implemented by means of software plus necessary general hardware platforms, or of course may be implemented by means of hardware. Based on such understanding, the foregoing technical solutions may be embodied essentially or in part in the form of a software product, which may be stored in a computer-readable storage medium, such as a ROM/RAM, a magnetic disk, an optical disk, etc., including several instructions to cause a computer device (which may be a personal computer, a server, or a network device, etc.) to perform the various embodiments or methods of some parts of the embodiments.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and are not limiting; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims (10)
1. The calculation method of the welding value of the butt annular weld is characterized by comprising the following steps of:
dividing grids for a pre-established butt annular welding model, and setting material characteristics and welding paths;
setting corresponding initial conditions, boundary conditions and a heat source model in the butt annular welding model;
and defining a target working condition, and determining a temperature field and a stress field according to the butt joint annular welding model.
2. The method of calculating a butt girth weld numerical value according to claim 1, further comprising, before the step of meshing the pre-established butt girth weld model to set the material properties and the welding path:
respectively establishing a three-dimensional geometric model based on the physical structures of the first welding piece, the second welding piece and the welding seam;
and determining a butt annular welding model based on the three-dimensional geometric model.
3. The method for calculating the welding value of the butt annular weld according to claim 1, wherein the meshing of the pre-established butt annular welding model, setting the material characteristics and the welding path, comprises:
dividing grids of a pre-established butt joint annular welding model according to preset grid division rules;
and setting material characteristics and establishing a welding path based on the material thermophysical properties and mechanical properties of the butt annular welding model.
4. The method for calculating a welding value of a butt annular weld according to claim 3, wherein the meshing of the pair of pre-established butt annular weld models according to a preset meshing rule specifically includes:
determining a model minimum symmetry unit based on the geometric symmetry of the butt annular welding model;
according to the preset grid division rule, grid division is conducted on the minimum symmetrical unit of the model; wherein, the grid cells close to the weld joint area are densely divided, and the grid cells far away from the weld joint area are sparsely divided;
and determining a butted annular welding model after grid division based on the minimum symmetric unit of the model after grid division.
5. The butt girth weld welding numerical calculation method according to any one of claims 1 to 4, wherein the initial conditions include: initial temperature and ambient temperature; the boundary condition is a displacement constraint condition; the heat source model is a double-ellipsoid thermal element model.
6. The method for calculating a welding value of a butt girth weld according to claim 5, wherein the displacement constraint condition is that the weldment is not displaced during the welding process.
7. The method for calculating the welding value of the butt annular weld according to any one of claims 1 to 4, wherein the defining the target working condition, according to the butt annular welding model, determines a temperature field and a stress field, specifically includes:
defining a target working condition, and determining a welding step and a cooling step;
and determining a temperature field and a stress field according to the butt annular welding model based on the welding step and the cooling step.
8. A butt girth weld numerical calculation system, comprising: a model setting unit, a parameter setting unit and a numerical value calculating unit;
the model setting unit is used for meshing a pre-established butt annular welding model and setting material characteristics and welding paths;
the parameter setting unit is used for setting corresponding initial conditions, boundary conditions and a heat source model in the butt annular welding model;
and the numerical calculation unit is used for defining a target working condition and determining a temperature field and a stress field according to the butt joint annular welding model.
9. An electronic device comprising a memory and a processor, said processor and said memory completing communication with each other via a bus; the memory stores program instructions executable by the processor, the processor invoking the program instructions capable of performing the butt girth weld numerical calculation method of any one of claims 1 to 7.
10. A non-transitory computer readable storage medium having stored thereon a computer program, which when executed by a processor, implements the butt girth weld numerical calculation method of any one of claims 1 to 7.
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| CN117428363B (en) * | 2023-12-20 | 2024-02-23 | 贵州省公路工程集团有限公司 | Welding method of unloading device |
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