CN117182369A - Welding and annealing deformation control method for steel bridge deck unit - Google Patents
Welding and annealing deformation control method for steel bridge deck unit Download PDFInfo
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- CN117182369A CN117182369A CN202310877045.6A CN202310877045A CN117182369A CN 117182369 A CN117182369 A CN 117182369A CN 202310877045 A CN202310877045 A CN 202310877045A CN 117182369 A CN117182369 A CN 117182369A
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 108
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- 238000000137 annealing Methods 0.000 title claims abstract description 47
- 238000010438 heat treatment Methods 0.000 claims abstract description 30
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- 238000004364 calculation method Methods 0.000 claims abstract description 16
- 238000003825 pressing Methods 0.000 claims description 11
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Abstract
The application discloses a welding and annealing deformation control method of a steel bridge deck unit, which belongs to the technical field of steel structure bridge manufacture and comprises the following steps: s1, collecting relevant parameters of a steel bridge deck, S2, performing finite element simulation, S3, performing finite element simulation of an annealing treatment process on the basis of the simulation of the step S2, obtaining deformation of a annealed steel bridge deck unit, S4, based on the steps S2 and S3, obtaining a practical calculation formula of maximum deformation of the steel bridge deck unit after welding and after heat treatment, S5, based on the deformation obtained in the step S4, setting reverse deformation on a reverse deformation jig, fixing the steel bridge deck unit on the reverse deformation jig, welding according to a preset welding process, and S6, performing annealing treatment according to a preset annealing process.
Description
Technical Field
The application mainly relates to the technical field of steel structure bridge manufacture, in particular to a welding and annealing deformation control method of a steel bridge deck unit.
Background
The steel bridge is a bridge with steel materials as main bearing structures, namely, a steel structure bridge, a steel bridge, a rigid connection formed by a beam and legs or pier (platform) bodies, and the structural form can be divided into a portal rigid frame bridge, an oblique leg rigid frame bridge, a T-shaped rigid frame bridge and a continuous rigid frame bridge.
The main structural formula of the orthotropic slab steel bridge deck, however, a large amount of residual stress is generated in the welding process of the orthotropic slab steel bridge deck, weak parts of metallographic structures and mechanics of materials are formed, and the weak parts can cause diseases such as deformation, early cracking, stress corrosion, fatigue fracture, brittle fracture and the like when a component operates, and can also reduce the bearing capacity of the component, influence the use reliability of a bridge structure and directly influence the operation safety and the service life of the structure.
In order to solve the problems, a process of carrying out integral annealing after welding the steel bridge deck units appears in China, residual stress of the orthotropic steel bridge deck is reduced through annealing treatment, residual stress and welding defects near welding seams are reduced, fatigue life of the orthotropic steel bridge deck can be prolonged, a new technical measure is provided for solving the bridge structure problems of complex welding details and huge number of welding seams, although annealing treatment can reduce welding residual stress and welding defects of the orthotropic steel bridge deck, more or less deformation is inevitably generated in the annealing process, which is to be avoided in the steel bridge processing process, but related research on deformation of the orthotropic steel bridge deck in the annealing process is not reported at present, related test data are lost, and the scheme is hindered from popularization.
Based on the method, the welding and annealing deformation control process of the steel bridge deck unit is provided, deformation control in the welding and annealing process of the orthotropic steel bridge deck is guided, so that the welding deformation of the orthotropic steel bridge deck is controlled, the key links of construction success and failure of a large-span steel structure bridge are related, the deformation of the steel bridge deck unit is accurately controlled, the method is very important for improving the assembly precision of the structure and reducing the manufacturing cost, positive significance is provided for reducing the deformation after the welding and annealing of the bridge deck and improving the manufacturing and processing efficiency of the bridge deck, and meanwhile, the method is also beneficial for popularization of the annealing process of the orthotropic steel bridge deck.
Disclosure of Invention
The technical scheme of the application aims at the technical problem that the prior art is too single, provides a solution which is obviously different from the prior art, and particularly mainly provides a welding and annealing deformation control method of a steel bridge deck unit, which is used for solving the technical problem of welding and annealing post-deformation control of an orthotropic steel bridge deck unit.
The technical scheme adopted for solving the technical problems is as follows:
a welding and annealing deformation control method of a steel bridge deck unit comprises the following steps:
s1: collecting the unit size of the steel bridge deck, welding process parameters and parameter values, annealing treatment parameters and parameter values;
s2: performing finite element simulation on the welding process of the steel bridge deck unit based on the parameters collected in the step S1 to obtain deformation of the steel bridge deck unit after welding is completed;
s3: carrying out finite element simulation of an annealing treatment process on the basis of the simulation of the step S2 according to the annealing process parameters of the steel bridge deck unit to obtain the deformation of the annealed steel bridge deck unit;
s4: based on the deformation obtained in the step S2 and the step S3, obtaining a practical calculation formula of the maximum deformation of the steel bridge deck unit after welding and after heat treatment;
s5: setting reverse deformation on the reverse deformation jig frame based on the deformation amount obtained in the step S4, and fixing the steel bridge deck unit on the reverse deformation jig frame for welding according to a preset welding process;
s6: and carrying out annealing treatment according to a preset annealing process.
Preferably, the annealing parameters in step S1 include a heating rate, a cooling rate, a holding temperature, and a holding time.
Preferably, the finite element simulation in the steps S2 and S3 is based on a thermal elastoplastic theory, which is a theoretical basis of the finite element simulation, and the application finds the relation between the above parameters and the welding annealing deformation through the finite element simulation of multiple parameters (plate thickness, weld bead number, energy input and the like), and determines the empirical formula of the patent, so that the welding annealing deformation can be rapidly determined through the empirical formula when similar steel bridge panels are welded and annealed later, and thus, the reverse deformation is applied, and the effect of deformation control is achieved;
the three-dimensional thermal elastoplastic finite element method generally consumes a great deal of time, and is completed by professionals, deformation can be rapidly predicted through the formula, and time is saved.
Preferably, in step S4, the practical calculation of the maximum deformation after welding and after heat treatment of the steel bridge deck units is based on the inherent strain theory, and is obtained by the following formula:
wherein: θ is angular deformation (rad), Δ is total deformation of transverse bending (mm), f is maximum deflection of longitudinal bending (mm), ζ is total proportional coefficient of transverse inherent strain, α is thermal expansion coefficient, c is specific heat, ρ is density, E is weld line energy (J/mm), td is thickness (mm) of steel cover plate (2), N is half of total number of weld lines of steel bridge panel unit (1), li is distance (mm) of ith weld line from outer edge of steel bridge panel unit (1), k is total proportional coefficient of longitudinal inherent strain, I is section moment of inertia of steel bridge panel unit (1), L is length (mm) of steel bridge panel unit (1), and N is half of total number of weld lines of steel bridge panel unit (1).
Preferably, the step S5 is that the reverse deformation jig has a size adjusting function, the reverse deformation jig comprises four supporting frames, each supporting frame is connected with a platform frame through rotation of a rotating shaft, two sides of two supporting frames located at the front and the tail are respectively provided with an upright, each upright is detachably connected with a pin shaft in mounting holes on two sides of the platform frame, each sliding groove on the upper side of the platform frame is internally and slidably connected with a pressing piece, the pressing piece is pressed in the sliding groove through a jack and is close to each pressing piece, one side of the pressing piece is provided with a reverse deformation adjusting component, the reverse deformation adjusting component comprises a mounting frame, seven hydraulic cylinders are arranged in the mounting frame, one hydraulic cylinder is located at the middle position inside the mounting frame, the other six hydraulic cylinders are symmetrically arranged on two sides of the hydraulic cylinders located at the middle position, electromagnetic valves are respectively arranged on pipelines of the two hydraulic cylinders located at the middle position, the movable ends of the seven hydraulic cylinders in the mounting frame are hinged together to form a pressing piece, the pressing piece is formed by a plurality of small steel sheets in a hinged combination, the pressing piece is pressed by the jack, the hydraulic bridge is pushed by the hydraulic bridge, and the hydraulic bridge is placed on the hydraulic bridge through the high-level adjusting device, and the hydraulic bridge is well pressed by the hydraulic bridge, and the purpose is achieved by the high-level driving device.
Preferably, the steel bridge deck unit comprises a steel cover plate and U-shaped longitudinal ribs welded on the lower surface of the steel cover plate, the U-shaped longitudinal ribs are arranged along the longitudinal direction of the steel cover plate, the number of the U-shaped longitudinal ribs arranged along the transverse direction of the steel cover plate is multiple, and the U-shaped longitudinal ribs are welded with the steel cover plate.
Preferably, the thickness of the steel cover plate is 14-24 mm, the thickness of the U longitudinal ribs is 8-12 mm, and the center distance between any two adjacent U longitudinal ribs is 600-800 mm.
Compared with the prior art, the application has the beneficial effects that:
according to the method, the actual welding parameters and heat treatment parameters are adopted to carry out welding and heat treatment simulation calculation, so that the deformation law and deformation values (strain field distribution and deformation size) of the welded and heat treated steel bridge deck units are obtained, the practical calculation formula of the maximum deformation of the welded and heat treated deck units is obtained, and the final deformation of the steel bridge deck units is reduced by applying corresponding reverse deformation when the U-ribbed top plate is welded.
The application will be explained in detail below with reference to the drawings and specific embodiments.
Drawings
FIG. 1 is a schematic view of the structure of a steel deck unit of the present application;
FIG. 2 is a schematic view of the structure of the reverse deformation jig of the application;
FIG. 3 is a schematic diagram of the connection of symmetrically distributed hydraulic cylinder conduits to solenoid valves according to the present application;
FIG. 4 is a schematic structural view of the geometric model of the present application;
FIG. 5 is a schematic representation of the applied mechanical constraint of the present application;
FIG. 6 is a schematic diagram showing temperature profiles during a spot weld and post weld heat treatment process on a weld according to the present application;
FIG. 7 is a cloud chart of residual stress distribution after the steel box girder of the present application is welded;
FIG. 8 is a cloud chart of residual stress distribution after heat treatment of the steel box girder of the present application;
FIG. 9 is a cloud chart of deformation distribution of the steel box girder of the present application after welding;
fig. 10 is a cloud image of deformation distribution after heat treatment of the steel box girder of the present application.
Description of the drawings: 1. a steel bridge deck unit; 2. a steel cover plate; 3. u-shaped longitudinal ribs; 4. a support frame; 5. a platform stand; 6. a column; 7. a pressing member; 8. an inverse deformation adjustment assembly; 81. a mounting frame; 82. a hydraulic cylinder; 83. a contact member; 84. a solenoid valve.
Detailed Description
In order that the application may be more fully understood, a more particular description of the application will be rendered by reference to the appended drawings, in which several embodiments of the application are illustrated, but which may be embodied in different forms and are not limited to the embodiments described herein, which are, on the contrary, provided to provide a more thorough and complete disclosure of the application.
It will be understood that when an element is referred to as being "mounted" on another element, it can be directly on the other element or intervening elements may be present, and when an element is referred to as being "connected" to the other element, it may be directly connected to the other element or intervening elements may also be present, the terms "vertical", "horizontal", "left", "right" and the like are used herein for the purpose of illustration only.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly connected to one of ordinary skill in the art to which this application belongs, and the knowledge of terms used in the description of this application herein for the purpose of describing particular embodiments is not intended to limit the application, and the term "and/or" as used herein includes any and all combinations of one or more of the associated listed items.
Finite element simulation was performed by calculation using a three-dimensional thermoplastic finite element method, with reference to the following calculation example 1:
geometric model: according to the actual structural size of the steel box girder, the welding and heat treatment numerical simulation is carried out by adopting equal-proportion scaling simulation, the scaling is 1/4 of that of an original model, the length of a bottom plate is 3000mm, the width of the bottom plate is 600mm, a U rib is welded on the bottom plate, a three-dimensional hexahedral unit is adopted for dividing grids, the geometric model after dividing the units is shown in fig. 4, the number of units is 15804, and the number of nodes is 21595.
The calculation method comprises the following steps: the welding numerical simulation adopts a temperature curve method, namely a welding temperature field is simulated according to an actual welding process, a temperature curve at a central node of a welding line is extracted, the temperature curve is used as a heat source to be applied to the welding line of the geometric model, and then welding deformation is calculated. The welding process uses the performance of unfilled materials to simulate the gradual filling of weld metal, and the thermal physical and mechanical performance parameters of the materials adopt the performance of Q345 materials. The constraints imposed by the weld mechanics calculation are shown in fig. 5.
In the numerical simulation of postweld heat treatment, a temperature curve is applied according to the temperature heating rate, peak temperature, heat preservation time and cooling rate in the heat treatment process to simulate a heat treatment temperature field, and then creep deformation of the material is considered in mechanical calculation. After calculation, the residual stress and deformation after welding and heat treatment were analyzed.
Calculation results:
FIG. 6 is a graph of the temperature during spot welding and post-weld heat treatment of a weld, where it can be seen that the maximum temperature at the weld is about 1550℃, the peak temperature of the heat treatment is 600℃, the heating rate is 220℃/h, and the holding time is 25 minutes. The average cooling rate at temperatures above 400 c is about 215 c/h.
Fig. 7 is a cloud chart of residual stress distribution after the steel box girder is welded, and it can be seen from the figure that residual stress in the transverse direction and the plate thickness direction after welding is smaller, the maximum value is lower than 100MPa, the longitudinal residual stress is larger, the maximum value is about 437MPa, and the equivalent stress is about 393MPa.
Fig. 8 is a cloud graph of residual stress distribution after heat treatment of steel box girders, which has substantially the same trend of stress distribution as compared with residual stress after welding, but significantly reduced residual stress after heat treatment, especially longitudinal residual stress and equivalent stress. The maximum value of the longitudinal residual stress after heat treatment is about 150MPa, the reduction is about 66%, the maximum value of the equivalent stress is 130MPa, and the reduction is about 69%. Therefore, after heat treatment, residual stress peaks are reduced, stress distribution is more uniform, maximum shear stress is reduced, and safety of a welding structure is improved.
FIG. 9 is a cloud chart of deformation distribution after the steel box girder is welded, and as can be seen from the figure, transverse deformation is mainly represented by shrinkage deformation of the U-shaped ribs, and the deformation amount is about 0.17mm; the longitudinal deformation is mainly represented by shrinkage deformation of the bottom plate, and the deformation amount is about 0.5mm; the deformation in the plate thickness direction is mainly represented by upward deflection deformation of the middle part of the steel box girder, the maximum value of the deformation is about 0.69mm, and the maximum value of the total deformation is about 0.73mm.
Fig. 10 is a cloud chart of deformation distribution after heat treatment of the steel box girder, wherein the deformation trend is basically the same, the transverse deformation and longitudinal deformation values are smaller, the maximum longitudinal deformation is reduced from 0.49mm after welding to 0.21mm, the deformation distribution change in the plate thickness direction is larger, although the middle part of the steel box girder is also deformed upwards, the deformation value is reduced, the flat plates mainly deformed at the two sides of the U-shaped rib are tilted upwards, the maximum deformation is about 0.4mm, and the maximum total deformation is about 0.43mm.
Example 1, please refer to figures 1-3,
an annealing process of a steel deck unit 1, as shown in fig. 1, comprising the steps of:
s1: collecting the size, welding process parameters and parameter values, annealing treatment parameters and parameter values of the steel bridge deck unit 1;
the bridge deck unit of this processing material is Q345qD, and length 10m, wide 3m sets up 4U longitudinal ribs, and wherein apron thickness 20mm, U longitudinal rib thickness 8mm.
The welding method is adopted: FCAW welding material: E501T-1 (phi 1.2) ship position welding semi-automatic CO2 gas shielded welding trolley welding.
Annealing parameters: the temperature is 600 ℃, the heating rate is 220 ℃/h, and the temperature is kept for 25 minutes. The average cooling rate at temperatures above 400 c is about 215 c/h.
S2: performing finite element simulation on the welding process of the steel bridge deck unit 1 based on the parameters collected in the step S1 to obtain deformation of the steel bridge deck unit 1 after welding is completed;
s3: carrying out finite element simulation of an annealing treatment process on the basis of simulation in the step S2 according to the annealing process parameters of the steel bridge deck unit 1 to obtain deformation of the annealed steel bridge deck unit 1;
the project adopts a three-dimensional thermal elastoplastic finite element method to calculate the welding and heat treatment process of the steel box girder, and analyzes the deformation distribution after welding and heat treatment.
S4: based on the deformation obtained in step S2 and step S3, a practical calculation formula of the maximum deformation of the steel bridge deck unit 1 after welding and after heat treatment is obtained, specifically as follows:
TABLE 1
As can be seen from Table 1, the total deformation in bending was found to be 35mm under the above-described calculation parameters.
S5: and (3) setting the reverse deformation on the reverse deformation jig based on the deformation obtained in the step S4, wherein the reverse deformation is 62mm. The steel bridge deck unit 1 is fixed on the reverse deformation jig frame and welded according to a predetermined welding process.
S6: and carrying out annealing treatment according to a preset annealing process.
While the application has been described above with reference to the accompanying drawings, it will be apparent that the application is not limited to the embodiments described above, but is intended to be within the scope of the application, as long as such insubstantial modifications are made by the method concepts and technical solutions of the application, or the concepts and technical solutions of the application are applied directly to other occasions without any modifications.
Claims (7)
1. The welding and annealing deformation control method of the steel bridge deck unit is characterized by comprising the following steps of:
s1: collecting the size, welding process parameters and parameter values, annealing treatment parameters and parameter values of the steel bridge deck unit (1);
s2: performing finite element simulation on the welding process of the steel bridge deck unit (1) based on the parameters collected in the step S1 to obtain deformation of the steel bridge deck unit (1) after welding is completed;
s3: carrying out finite element simulation of an annealing treatment process on the basis of simulation in the step S2 according to annealing process parameters of the steel bridge deck unit (1) to obtain deformation of the annealed steel bridge deck unit (1);
s4: based on the deformation obtained in the step S2 and the step S3, obtaining a practical calculation formula of the maximum deformation of the steel bridge deck unit (1) after welding and after heat treatment;
s5: setting reverse deformation on the reverse deformation jig based on the deformation obtained in the step S4, and fixing the steel bridge deck unit (1) on the reverse deformation jig for welding according to a preset welding process;
s6: and carrying out annealing treatment according to a preset annealing process.
2. The method for controlling welding and annealing deformation of steel bridge deck units according to claim 1, wherein the annealing parameters in step S1 include a heating rate, a cooling rate, a heat-preserving temperature, and a heat-preserving time.
3. The method for controlling welding and annealing deformation of steel deck units according to claim 1, wherein the finite element simulation in steps S2 and S3 is based on the theory of thermal elastoplasticity.
4. A method for controlling welding and annealing deformation of steel bridge deck units according to claims 1-3, characterized in that the practical calculation of maximum deformation after welding and after heat treatment of steel bridge deck units (1) in step S4 is based on the inherent strain theory, and is obtained by the following formula:
wherein: θ is angular deformation (rad), Δ is total deformation of transverse bending (mm), f is maximum deflection of longitudinal bending (mm), ζ is total proportional coefficient of transverse inherent strain, α is thermal expansion coefficient, c is specific heat, ρ is density, E is weld line energy (J/mm), td is thickness (mm) of steel cover plate (2), N is half of total number of weld lines of steel bridge panel unit (1), li is distance (mm) of ith weld line from outer edge of steel bridge panel unit (1), k is total proportional coefficient of longitudinal inherent strain, I is section moment of inertia of steel bridge panel unit (1), L is length (mm) of steel bridge panel unit (1), and N is half of total number of weld lines of steel bridge panel unit (1).
5. The welding and annealing deformation control method of a steel bridge deck unit according to claim 1, wherein in the step S5, the reverse deformation jig has the function of adjusting the size, the reverse deformation jig comprises four supporting frames (4), each supporting frame (4) is rotatably connected with a platform frame (5) through a rotating shaft, two sides of two supporting frames (4) positioned at the front and rear positions are respectively provided with an upright post (6), each upright post (6) is detachably connected with a pin shaft in mounting holes at two sides of the platform frame (5), each sliding groove at the upper side of the platform frame (5) is respectively and slidably connected with a pressing piece (7), the pressing pieces (7) are pressed in the sliding grooves through a jack, one side close to each pressing piece (7) is respectively provided with a reverse deformation adjusting component (8), each reverse deformation adjusting component (8) comprises a mounting frame (81), seven hydraulic cylinders (82) are arranged in the mounting frame (81), one hydraulic cylinder (82) is positioned at an intermediate position inside the mounting frame (81), the rest six hydraulic cylinders (82) are symmetrically arranged at two intermediate positions in the two symmetric hydraulic cylinders (82), the two electromagnetic valves (82) are respectively and the two electromagnetic valves (82) are symmetrically arranged at the two mutually communicated positions at the two sides of the pipeline (82), the abutting piece (83) is formed by hinging and combining a plurality of small steel sheets.
6. The welding and annealing deformation control method of a steel bridge deck unit according to claim 1, wherein the steel bridge deck unit (1) includes a steel deck plate (2) and U longitudinal ribs (3) welded to the lower surface of the steel deck plate (2), the U longitudinal ribs (3) are provided along the longitudinal direction of the steel deck plate (2), the number of the U longitudinal ribs (3) provided along the transverse direction of the steel deck plate (2) is plural, and the U longitudinal ribs (3) and the steel deck plate (2) are welded.
7. The welding and annealing deformation control method of steel bridge deck unit according to claim 6, characterized in that the thickness of the steel cover plate (2) is 14-24 mm, the thickness of the U longitudinal ribs (3) is 8-12 mm, and the center distance between any adjacent U longitudinal ribs (3) is 600-800 mm.
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| CN105397369A (en) * | 2015-12-16 | 2016-03-16 | 沈阳中辰钢结构工程有限公司 | Welding reversible deformation technology for steel box girder top plate unit |
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| CN111334658A (en) * | 2020-04-07 | 2020-06-26 | 西南交通大学 | Method for reducing welding residual stress of orthotropic steel bridge deck |
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| CN214134676U (en) * | 2020-12-11 | 2021-09-07 | 洛阳豫安金属结构有限公司 | Anti-deformation jig frame for welding steel box girder bridge deck plate |
| CN214291685U (en) * | 2021-02-01 | 2021-09-28 | 中建五洲工程装备有限公司 | Anti-deformation jig frame for slidable track |
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2023
- 2023-07-18 CN CN202310877045.6A patent/CN117182369B/en active Active
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| CN105397369A (en) * | 2015-12-16 | 2016-03-16 | 沈阳中辰钢结构工程有限公司 | Welding reversible deformation technology for steel box girder top plate unit |
| CN109570708A (en) * | 2018-11-15 | 2019-04-05 | 中铁宝桥（扬州）有限公司 | A kind of orthotropic steel bridge deck U rib K-type connector complex welding method |
| CN111375930A (en) * | 2018-12-27 | 2020-07-07 | 中车唐山机车车辆有限公司 | Welding deformation control method |
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| CN214134676U (en) * | 2020-12-11 | 2021-09-07 | 洛阳豫安金属结构有限公司 | Anti-deformation jig frame for welding steel box girder bridge deck plate |
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