WO2024055271A1 - 一种极端环境下超长寿命服役结构抗疲劳及安全调控方法 - Google Patents

一种极端环境下超长寿命服役结构抗疲劳及安全调控方法 Download PDF

Info

Publication number
WO2024055271A1
WO2024055271A1 PCT/CN2022/119223 CN2022119223W WO2024055271A1 WO 2024055271 A1 WO2024055271 A1 WO 2024055271A1 CN 2022119223 W CN2022119223 W CN 2022119223W WO 2024055271 A1 WO2024055271 A1 WO 2024055271A1
Authority
WO
WIPO (PCT)
Prior art keywords
fatigue
ultra
service
life
defect
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2022/119223
Other languages
English (en)
French (fr)
Inventor
朱明亮
轩福贞
朱刚
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
East China University of Science and Technology
Original Assignee
East China University of Science and Technology
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by East China University of Science and Technology filed Critical East China University of Science and Technology
Priority to PCT/CN2022/119223 priority Critical patent/WO2024055271A1/zh
Priority to CN202310143768.3A priority patent/CN117113543A/zh
Priority to US18/227,069 priority patent/US20240104482A1/en
Publication of WO2024055271A1 publication Critical patent/WO2024055271A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Images

Classifications

    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/10—Geometric CAD
    • G06F30/17—Mechanical parametric or variational design
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
    • G06Q10/063—Operations research, analysis or management
    • G06Q10/0639—Performance analysis of employees; Performance analysis of enterprise or organisation operations
    • G06Q10/06395—Quality analysis or management
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00—Testing or monitoring of control systems or parts thereof
    • G05B23/02—Electric testing or monitoring
    • G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0218—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
    • G05B23/0243—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults model based detection method, e.g. first-principles knowledge model
    • G05B23/0254—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults model based detection method, e.g. first-principles knowledge model based on a quantitative model, e.g. mathematical relationships between inputs and outputs; functions: observer, Kalman filter, residual calculation, Neural Networks
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00—Testing or monitoring of control systems or parts thereof
    • G05B23/02—Electric testing or monitoring
    • G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0259—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the response to fault detection
    • G05B23/0283—Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL]
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00—Testing or monitoring of control systems or parts thereof
    • G05B23/02—Electric testing or monitoring
    • G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0259—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the response to fault detection
    • G05B23/0286—Modifications to the monitored process, e.g. stopping operation or adapting control
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/20—Design optimisation, verification or simulation
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
    • G06Q10/067—Enterprise or organisation modelling
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q50/00—Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
    • G06Q50/04—Manufacturing
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q50/00—Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
    • G06Q50/10—Services
    • G06Q50/26—Government or public services
    • G06Q50/265—Personal security, identity or safety
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
    • G06F2119/02—Reliability analysis or reliability optimisation; Failure analysis, e.g. worst case scenario performance, failure mode and effects analysis [FMEA]
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
    • G06F2119/14—Force analysis or force optimisation, e.g. static or dynamic forces
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/30—Computing systems specially adapted for manufacturing

Definitions

  • the invention relates to the fields of mechanical structural strength and high-end equipment intelligent manufacturing. More specifically, it relates to a fatigue resistance and safety control method for ultra-long-life service structures in extreme environments.
  • Structural fatigue damage is one of the most typical failure forms in engineering. According to the number of cycles, it can be divided into low-cycle fatigue, high-cycle fatigue and ultra-high-cycle fatigue.
  • the first way is to directly use high-strength materials
  • the second method is the widely used surface strengthening technology
  • the purpose of the present invention is to provide a fatigue resistance and safety control method for ultra-long-life service structures in extreme environments, and to solve the problem in the existing technology that it is difficult to effectively prevent fatigue damage of ultra-long-life service structures.
  • the present invention provides a fatigue resistance and safety control method for ultra-long life service structures in extreme environments, which includes the following steps:
  • Step S1 Determine the fatigue fracture mode of the service structure in the long life stage. If it is the internal defect fracture mode, proceed to step S2;
  • Step S2 According to the interaction principle of defect-matrix, obtain the cracking mechanism of ultra-high cycle fatigue internal defects in service structures in air environment;
  • Step S3 Considering environmental factors, clarify the internal defect-matrix-environment interaction mechanism of ultra-high cycle fatigue under service conditions and obtain the environmental weakening coefficient;
  • Step S4 Comprehensive consideration of environmental factors, establish a theoretical model for ultra-high cycle fatigue life prediction of defect-load-life relationship under service conditions;
  • Step S5 According to the ultra-high cycle fatigue life prediction theoretical model, the material metallurgy and manufacturing process parameters, structural strength design parameters, structural service stress and environmental parameters are regulated based on the design/manufacturing integration concept.
  • step S1 further includes the following steps:
  • the traditional fatigue resistance theoretical model includes a low-cycle fatigue Manson-Coffin model and a high-cycle fatigue Basquin model.
  • the matrix-defect interaction principle in step S2 is that local plasticity around the defect causes damage to the microstructure of the matrix under cyclic loading.
  • the interaction mechanism of the defect-matrix-environment in step S3 is that the microstructural damage of the matrix is caused by the coupling effect of local plasticity around the defect, chemical elements and temperature under cyclic loading.
  • the expression corresponding to the environmental weakening coefficient H in step S3 is:
  • ⁇ (environment) is the fatigue strength under service conditions
  • ⁇ (air) is the fatigue strength in air environment
  • N (environment) is the fatigue life under service conditions
  • N air is the fatigue life in air environment.
  • the corresponding expression of the ultra-high cycle fatigue life prediction theoretical model in step S4 is:
  • ⁇ a is the fatigue stress amplitude
  • D is the relative position of the defect
  • ⁇ and C are both fitting constants
  • N f fatigue life
  • ⁇ is the material constant
  • d is the diameter of the fatigue test bar
  • d inc is the minimum distance from the center point of the defect to the outer surface of the test rod
  • Z is the fatigue life control parameter.
  • step S5 the material metallurgy and manufacturing process parameters are controlled according to the ultra-high cycle fatigue life prediction theoretical model, which further includes the following steps:
  • Step S511 According to the ultra-high cycle fatigue life prediction theoretical model, control the metallurgy and manufacturing process, and conduct material design and material manufacturing;
  • Step S512 Conduct fatigue testing on the material and evaluate the test data
  • Step S513 Compare the evaluation result with the expected index. If the evaluation result meets the expected index requirements, the current material is an ultra-long life anti-fatigue material, and the process ends. If the evaluation result does not meet the expected index requirements, the metallurgical and manufacturing process parameters After performing the regulation, step S511 is entered again until the evaluation result meets the expected index requirements.
  • step S5 the structural strength design parameters are adjusted according to the ultra-high cycle fatigue life prediction theoretical model, which further includes the following steps:
  • Step S521 Carry out structural fatigue design and material fatigue design according to the fatigue fracture mode in the long life stage of the service structure, and obtain structural strength design parameters;
  • Step S522 Verify and check the structural strength design parameters based on the ultra-high cycle fatigue life prediction theoretical model
  • Step S523 Compare the verification and check results with the design requirements. If the verification and check results meet the design requirements, the current structural strength design parameters are the ultra-long life anti-fatigue design parameters, and the process ends. If the verification and check results do not meet the design requirements , then re-enter step S521 to regulate the structural strength design parameters until the verification results meet the design requirements.
  • step S5 the structural service stress and environmental parameters are regulated according to the ultra-high cycle fatigue life prediction theoretical model, which further includes the following steps:
  • Step S531 Establish a digital twin model by combining the ultra-high cycle fatigue life prediction theoretical model with the structural strength design parameters;
  • Step S532 Perform safety simulation analysis on the digital twin model
  • the invention proposes a fatigue resistance and safety control method for ultra-long life service structures, which combines material metallurgy, structural design, and manufacturing processes to comprehensively consider the ultra-high cycle fatigue failure problem of service structures and simultaneously consider the design during fatigue resistance design.
  • the coupling effect with manufacturing can enhance the collaboration between design and manufacturing, shorten the design and manufacturing process, effectively improve the fatigue resistance of materials and structures, and thus ensure safe operation and maintenance in service.
  • Figure 1 reveals a flow chart of a fatigue resistance and safety control method for ultra-long life service structures based on design/manufacturing integration according to an embodiment of the present invention
  • Figure 2 reveals a flow chart of a case of regulating ultra-long life anti-fatigue materials according to an embodiment of the present invention
  • Figure 3 reveals a flow chart of a case of strength regulation of an ultra-long life anti-fatigue structure according to an embodiment of the present invention
  • Figure 4 reveals a flow chart of a case of safe service regulation of ultra-long life structures according to an embodiment of the present invention.
  • the generation of internal defects is related to material metallurgical factors, while the performance of the material matrix depends on the design and manufacturing process, and environmental factors represent service conditions.
  • the combination of the three requires the coordination and unity of material design, metallurgy and manufacturing processes, and service environment.
  • the ultimate goal of ultra-high cycle fatigue research is to "find ways to prevent structural breakage" to ensure the long-life service safety and reliability of the structure.
  • the present invention proposes a fatigue resistance and safety control method for ultra-long-life service structures in extreme environments. It comprehensively considers the influence of material strength, internal defects and external environment, and optimizes the material alloy composition design, metallurgical conditions, and structural manufacturing. Factors such as process and service conditions should be taken into account to establish "design/manufacturing integration" structural breakage prevention technology to achieve long-life safe operation and maintenance of service structures.
  • Figure 1 reveals a flow chart of an anti-fatigue and safety control method for an ultra-long-life service structure based on design/manufacturing integration according to an embodiment of the present invention.
  • the present invention proposes an ultra-long-life service structure in extreme environments.
  • the fatigue resistance and safety control method of service structures includes the following steps:
  • Step S1 Determine the fatigue fracture mode of the service structure in the long life stage. If it is the internal defect fracture mode, proceed to step S2;
  • Step S2 According to the interaction principle of defect-matrix, obtain the cracking mechanism of ultra-high cycle fatigue internal defects in service structures in air environment;
  • Step S3 Considering environmental factors, clarify the internal defect-matrix-environment interaction mechanism of ultra-high cycle fatigue under service conditions and obtain the environmental weakening coefficient;
  • Step S4 Comprehensive consideration of environmental factors, establish a theoretical model for ultra-high cycle fatigue life prediction of defect-load-life relationship under service conditions;
  • Step S5 According to the ultra-high cycle fatigue life prediction theoretical model, the material metallurgy and manufacturing process parameters, structural strength design parameters, structural service stress and environmental parameters are regulated based on the design/manufacturing integration concept.
  • the anti-fatigue and safety control method and system of ultra-long-life service structures in extreme environments based on design/manufacturing integration provided by the present invention simultaneously considers the coupling effect of design and manufacturing during anti-fatigue design, which can shorten the design and manufacturing process and effectively Improve the fatigue resistance of materials and structures.
  • this method embodies the full life cycle and integrated anti-breakage control route of design, manufacturing and operation and maintenance, promotes the compatibility and coordination of material design, metallurgy and manufacturing processes, and supports the ultra-long life service structure of a series of high-end equipment. Anti-breakage design, manufacturing and operation and maintenance.
  • Step S1 Determine the fatigue fracture mode of the service structure in the long life stage. If it is the internal defect fracture mode, proceed to step S2.
  • the fatigue fracture modes of long-life service structures are divided into surface defect-induced cracking and internal defect-induced cracking.
  • step S1 the surface and internal cracking modes are distinguished. If it is a surface defect cracking mode, the anti-fatigue design is carried out according to the traditional anti-fatigue theoretical model. If it is an internal defect cracking mode, step S2 is entered for fatigue resistance design.
  • Basquin formula and Manson-Coffin formula respectively select stress amplitude and strain amplitude as parameters for evaluation.
  • the Manson-Coffin model is a well-known strain-life relationship model in the local stress-strain method. It is used to directly predict the finite life of constant amplitude fatigue. In addition to the overall materials, the materials involved include welded joints and new materials, and its applications are also expanded. to short fatigue, variable amplitude fatigue, etc.
  • the Basquin model is used to describe the S-N curve relationship between fatigue life and stress.
  • Step S2 According to the interaction between the defect and the matrix, the cracking mechanism of ultra-high cycle fatigue internal defects in the air environment of the service structure is obtained.
  • the described matrix-defect interaction principle is that local plasticity around the defect causes damage to the microstructure of the matrix under cyclic loading.
  • Step S3 Considering environmental factors, clarify the internal defect-matrix-environment interaction mechanism of ultra-high cycle fatigue under service conditions and obtain the environmental weakening coefficient.
  • the described defect-matrix-environment interaction mechanism is that the local plasticity around the defect, the coupling effect of chemical elements and temperature under cyclic loading cause damage to the microstructure of the matrix.
  • ⁇ (environment) is the fatigue strength under service conditions
  • ⁇ (air) is the fatigue strength in air environment
  • N (environment) is the fatigue life under service conditions
  • N air is the fatigue life in air environment.
  • Step S4 Comprehensive consideration of environmental factors, establish a theoretical model for ultra-high cycle fatigue life prediction of defect-load-life relationship in service environment.
  • the ultra-high cycle fatigue life prediction theoretical model based on the cracking mechanism of internal micro-defects comprehensively considers the geometric size, location, morphology of internal micro-defects, factors affecting matrix performance and environmental factors.
  • ⁇ a is the fatigue stress amplitude
  • D is the relative position of the defect
  • ⁇ and C are both fitting constants
  • N f fatigue life
  • ⁇ is the material constant
  • d is the diameter of the fatigue test bar
  • d inc is the minimum distance from the center point of the defect to the outer surface of the test rod
  • Z is the fatigue life control parameter.
  • the d inc can be the minimum distance measured from the center point of the defect on the fatigue fracture scanning electron microscope photo to the outer surface of the test bar using image analysis software.
  • Step S5 According to the ultra-high cycle fatigue life prediction theoretical model, the material metallurgy and manufacturing process parameters, structural strength design parameters, structural service stress and environmental parameters are regulated based on the concept of design/manufacturing integration.
  • the material metallurgy and manufacturing process parameters are controlled based on the ultra-high cycle fatigue life prediction theoretical model.
  • Figure 2 reveals a flow chart of a case of regulating ultra-long life anti-fatigue materials according to an embodiment of the present invention.
  • step S5 material metallurgy and manufacturing process parameters are regulated according to the ultra-high cycle fatigue life prediction theoretical model. Further steps include:
  • Step S511 According to the ultra-high cycle fatigue life prediction theoretical model, control the metallurgy and manufacturing process, and conduct material design and material manufacturing;
  • the metallurgical and manufacturing processes are controlled based on the ultra-high cycle fatigue life prediction theoretical model, and the process parameters of material design and manufacturing are controlled based on the life prediction theoretical model.
  • material design includes strengthening the matrix and reducing inclusion size
  • material manufacturing includes surface manufacturing or internal manufacturing.
  • Step S512 performing fatigue test on the material and evaluating the test data
  • Step S513 Compare the evaluation result with the expected index. If the evaluation result meets the expected index requirements, the current material is an ultra-long life anti-fatigue material, and the process ends. If the evaluation result does not meet the expected index requirements, the metallurgical and manufacturing process parameters After performing the regulation, step S511 is entered again until the evaluation result meets the expected index requirements.
  • step S5 the structural strength design parameters are further controlled based on the ultra-high cycle fatigue life prediction theoretical model.
  • Figure 3 reveals a case process for regulating the strength of an ultra-long-life anti-fatigue structure according to an embodiment of the present invention.
  • step S5 the structural strength design parameters are regulated based on the ultra-high cycle fatigue life prediction theoretical model. Further steps include:
  • Step S521 Carry out structural fatigue design and material fatigue design according to the fatigue fracture mode in the long life stage of the service structure, and obtain structural strength design parameters;
  • the structural strength design parameters described are controlled based on the ultra-long life anti-fatigue material properties.
  • Structural strength design is carried out according to the fatigue fracture mode (referred to as failure mode) in the long life stage of the service structure.
  • Step S522 Verify and check the structural strength design parameters based on the ultra-high cycle fatigue life prediction theoretical model
  • Step S523 Compare the verification and check results with the design requirements. If the verification and check results meet the design requirements, the current structural strength design parameters are the ultra-long life anti-fatigue design parameters, and the process ends. If the verification and check results do not meet the design requirements , then re-enter step S521 to regulate the structural strength design parameters until the verification results meet the design requirements.
  • the design model corresponding to the ultra-long life anti-fatigue design parameters is used as the ultra-long life anti-fatigue design model.
  • the structural service stress and environmental parameters are further regulated.
  • the structural service stress and environmental parameters are regulated based on the ultra-long life anti-fatigue material and structural strength design parameters.
  • Figure 4 reveals a flow chart of a safe service control case for an ultra-long life structure according to an embodiment of the present invention.
  • step S5 the structural service stress and environmental parameters are calculated based on the ultra-high cycle fatigue life prediction theoretical model. Regulation further includes the following steps:
  • Step S531 Establish a digital twin model by combining the ultra-high cycle fatigue life prediction theoretical model with the structural strength design parameters;
  • service stress and environmental parameters (hereinafter referred to as service parameters) are updated together with the ultra-long life anti-fatigue material data and failure mechanisms obtained in the above steps to establish a theoretical model for ultra-high cycle fatigue life prediction.
  • Service parameters include stress levels and environmental parameters.
  • a digital model reflecting the real-time service status of the physical entity is established.
  • the digital model is a digital twin model.
  • Digital twins make full use of data such as physical models, sensor updates, and operation history to integrate multi-disciplinary, multi-physical quantities, multi-scale, and multi-probability simulation processes to complete mapping in virtual space to reflect the full life cycle of the corresponding physical equipment. process.
  • Step S532 Perform safety simulation analysis on the digital twin model
  • the digital twin model is embedded in the simulation software to perform safety simulation analysis.
  • the damage mode of the steam turbine blade is typical environmental ultra-high cycle fatigue damage.
  • the steam turbine blade is designed for fatigue resistance according to the anti-fatigue and safety control method of the ultra-long life service structure disclosed in the present invention. The specific steps are as follows:
  • Step S1 Determine the fatigue fracture mode of the steam turbine blade in the long life stage
  • the fatigue fracture modes of steam turbine blades in the long life stage include surface defect cracking and internal defect cracking;
  • Step S2 Based on the internal defect cracking mode, further determine the ultra-high cycle fatigue internal defect cracking mechanism of the steam turbine blade;
  • the principle of ultra-high cycle fatigue internal defect cracking in steam turbine blades in the air environment is that local plasticity around the defect causes damage to the microstructure of the matrix under cyclic loading.
  • Step S3 Considering environmental factors, clarify the ultra-high cycle fatigue internal defect-matrix-environment interaction mechanism under the service conditions of the steam turbine blade and obtain the environmental weakening coefficient, and obtain the cracking of ultra-high cycle fatigue internal defects under the steam turbine blade service conditions (corrosive environment) Factors affecting the mechanism and obtain the environmental weakening coefficient;
  • the cracking mechanism of ultra-high cycle fatigue internal defects in blades needs to consider the influence of hydrogen on the fatigue damage of the matrix microstructure around the defects.
  • Step S4 Comprehensively consider environmental factors, consider the influence of matrix-defect-hydrogen, and combine the failure mechanism and environmental weakening coefficient to establish a theoretical model for ultra-high cycle fatigue life prediction related to defects-load-life.
  • ⁇ a is the fatigue stress amplitude
  • area is the micro-defect projected area
  • ⁇ and C are fitting constants
  • N f is the fatigue life
  • D is the relative position of the defect
  • ⁇ is the material constant, which is affected by the environment
  • d is The diameter of the fatigue test bar
  • d inc is the minimum distance from the center point of the defect to the outer surface of the test bar
  • Z is the fatigue life control parameter.
  • Step S5 According to the ultra-high cycle fatigue life prediction theoretical model, the material metallurgy and manufacturing process parameters, structural strength design parameters, structural service stress and environmental parameters are regulated based on the concept of design/manufacturing integration.
  • step S5 further includes the following steps:
  • Step S51 as shown in Figure 2, regulate material metallurgy and manufacturing process parameters to obtain ultra-long life fatigue-resistant materials
  • Step S52 as shown in Figure 3, adjust the structural strength design parameters to obtain an ultra-long life anti-fatigue design model
  • Step S53 regulates structural service stress and environmental parameters to ensure design service safety.
  • the invention proposes a fatigue resistance and safety control method for ultra-long life service structures, which combines material metallurgy, structural design, and manufacturing processes to comprehensively consider the ultra-high cycle fatigue failure problem of service structures and simultaneously consider the design during fatigue resistance design.
  • the coupling effect with manufacturing can shorten the design and manufacturing process, effectively improve the fatigue resistance of materials and structures, and thus ensure safe operation and maintenance in service.

Landscapes

  • Business, Economics & Management (AREA)
  • Engineering & Computer Science (AREA)
  • Human Resources & Organizations (AREA)
  • Physics & Mathematics (AREA)
  • Strategic Management (AREA)
  • General Physics & Mathematics (AREA)
  • Economics (AREA)
  • Theoretical Computer Science (AREA)
  • Tourism & Hospitality (AREA)
  • General Business, Economics & Management (AREA)
  • Marketing (AREA)
  • Development Economics (AREA)
  • Educational Administration (AREA)
  • Entrepreneurship & Innovation (AREA)
  • General Health & Medical Sciences (AREA)
  • Game Theory and Decision Science (AREA)
  • Operations Research (AREA)
  • Quality & Reliability (AREA)
  • Primary Health Care (AREA)
  • Health & Medical Sciences (AREA)
  • Geometry (AREA)
  • Automation & Control Theory (AREA)
  • Evolutionary Computation (AREA)
  • Computer Security & Cryptography (AREA)
  • Manufacturing & Machinery (AREA)
  • Computer Hardware Design (AREA)
  • General Engineering & Computer Science (AREA)
  • Computational Mathematics (AREA)
  • Pure & Applied Mathematics (AREA)
  • Mathematical Optimization (AREA)
  • Mathematical Analysis (AREA)
  • Artificial Intelligence (AREA)
  • Mathematical Physics (AREA)
  • Investigating Strength Of Materials By Application Of Mechanical Stress (AREA)

Abstract

一种极端环境下超长寿命服役结构抗疲劳及安全调控方法，包括：判断服役结构的长寿命阶段疲劳断裂模式；根据缺陷-基体的交互作用原理，获得服役结构空气环境下超高周疲劳内部缺陷致裂机理；考虑环境因素，明晰服役条件下超高周疲劳内部缺陷-基体-环境交互作用机理并获取环境削弱系数；建立服役条件下的缺陷-载荷-寿命关联的超高周疲劳寿命预测理论模型；基于设计/制造一体化理念对材料冶金与制造工艺参数、结构强度设计参数、结构服役应力与环境参数进行调控。该方法可以增强设计与制造的协同性，缩短设计与制造流程，有效提高材料与结构抗疲劳能力，保障结构长周期服役安全。

Description

一种极端环境下超长寿命服役结构抗疲劳及安全调控方法 技术领域
本发明涉及机械结构强度与高端装备智能制造领域，更具体的说，涉及一种极端环境下超长寿命服役结构抗疲劳及安全调控方法。
背景技术
结构的疲劳破坏是工程中最典型的失效形式之一。按照循环周次可分为低周疲劳、高周疲劳和超高周疲劳。
近二十年来，核电装备、发动机部件、汽车承力部件、铁路轮轴与轨道、飞机、海岸结构、桥梁等现代工程装备与构件呈现低应力、长寿命服役新趋势。
目前，可以通过以下两种方式提升长寿命服役结构的抗疲劳性能：
第一种方式是直接选用高强度材料；
但是，材料的强度水平越高，对缺陷或环境致裂敏感性也相应的提高，即依赖提高材料强度水平以获得高疲劳抗力是不可行的，这使人们意识到“结构的断裂不仅仅是材料的问题”；
第二种方式是现有广泛应用的表面强化技术；
主要基于抗疲劳制造的理念，通过改变材料表层的微观结构、化学成分和应力状态，可以延长结构疲劳寿命，然而，这种使结构表面发生强化的技术，却使结构在长寿命条件下的裂纹更容易在内部缺陷处萌生，表面强化技术抗疲劳的结果，是使结构最终呈现出超高周疲劳特性，使人们意识到“表面强并不能有效防断”。
因此，目前迫切需要发展新的方法及工艺技术，对超长寿命服役结构的疲劳断裂进行安全调控。
发明内容
本发明的目的是提供一种极端环境下超长寿命服役结构抗疲劳及安全调控方法，解决现有技术对超长寿命服役结构的疲劳破坏难以进行有效防断的问题。
为了实现上述目的，本发明提供了一种极端环境下超长寿命服役结构抗疲劳及安全调控方法，包括以下步骤：
步骤S1、判断服役结构的长寿命阶段疲劳断裂模式，如果为内部缺陷致裂模式，则进入步骤S2；
步骤S2、根据缺陷-基体的交互作用原理，获得服役结构空气环境下超高周疲劳内部缺陷致裂机理；
步骤S3、考虑环境因素，明晰服役条件下超高周疲劳内部缺陷-基体-环境交互作用机理并获取环境削弱系数；
步骤S4、综合考虑环境因素，建立服役条件下的缺陷-载荷-寿命关联的超高周疲劳寿命预测理论模型；
步骤S5、根据超高周疲劳寿命预测理论模型，基于设计/制造一体化理念对材料冶金与制造工艺参数、结构强度设计参数、结构服役应力与环境参数进行调控。
在一实施例中，所述步骤S1，进一步包括以下步骤：
判断服役结构的长寿命阶段疲劳断裂模式，如果为表面缺陷致裂模式，则根据传统抗疲劳理论模型进行抗疲劳及安全调控。
在一实施例中，所述传统抗疲劳理论模型包括低周疲劳Manson-Coffin模型和高周疲劳Basquin模型。
在一实施例中，所述步骤S2的基体-缺陷交互作用原理为循环载荷下缺陷周围局部塑性导致基体微观组织损伤。
在一实施例中，所述步骤S3的缺陷-基体-环境的交互作用机理为循环载荷下缺陷周围局部塑性、化学元素与温度耦合作用导致基体微观组织损伤。
在一实施例中，所述步骤S3中的环境削弱系数H对应的表达式为：
Figure PCTCN2022119223-appb-000001
或
Figure PCTCN2022119223-appb-000002
σ (environment)为服役条件下的疲劳强度；
σ (air)为空气环境下的疲劳强度；
N (environment)为服役条件下的疲劳寿命；
N (air)为空气环境下的疲劳寿命。
在一实施例中，所述步骤S4的超高周疲劳寿命预测理论模型，对应的表达式为：
{σ a(area) 1/12} αN f＝C
Z＝σ a(area) 1/6D β；
D＝(d-d inc)/d；
其中，σ a为疲劳应力幅；
area为微缺陷投影面积；
D为缺陷的相对位置；
α，C均为拟合常数；
N f为疲劳寿命；
β为材料常数；
d为疲劳试棒直径；
d inc为缺陷的中心点到试棒外侧表面的最小距离；
Z为疲劳寿命控制参量。
在一实施例中，所述步骤S5中根据超高周疲劳寿命预测理论模型，进行材料冶金与制造工艺参数调控，进一步包括以下步骤：
步骤S511、根据超高周疲劳寿命预测理论模型，调控冶金与制作工艺，进行材料设计和材料制造；
步骤S512、对材料进行疲劳测试，对测试数据进行评估；
步骤S513、将评估结果与预期指标进行比较，如果评估结果满足预期指标要求，则当前材料为超长寿命抗疲劳材料，流程结束，如果评估结果不满足预期指标要求，则对冶金与制造工艺参数进行调控后重新进入步骤S511，直至评估结果满足预期指标要求。
在一实施例中，所述步骤S5中根据超高周疲劳寿命预测理论模型，进行结构强度设计参数调控，进一步包括以下步骤：
步骤S521、根据服役结构的长寿命阶段疲劳断裂模式进行结构疲劳设计和材料疲劳设计，获得结构强度设计参数；
步骤S522、基于超高周疲劳寿命预测理论模型对结构强度设计参数进行验证校核；
步骤S523、将验证校核结果与设计要求进行比较，如果验证校核结果满足设计要求，则当前结构强度设计参数为超长寿命抗疲劳设计参数，流程结束，如果验证校核结果不满足设计要求，则重新进入步骤S521，对结构强度设计参数进行调控，直至验证校核结果满足设计要求。
在一实施例中，所述步骤S5中根据超高周疲劳寿命预测理论模型，进行结构服役应力与环境参数调控，进一步包括以下步骤：
步骤S531、将超高周疲劳寿命预测理论模型结合结构强度设计参数建立数字孪生模型；
步骤S532、将数字孪生模型进行安全仿真分析；
步骤S533、如果安全仿真输出结果为安全，则当前服役应力与环境参数符合要求，流程结束，如果安全仿真输出结果为不安全，则对服役应力与环境参数进行调控，重新进入步骤S531，直至安全仿真输出结果为安全。
本发明提出的一种超长寿命服役结构抗疲劳及安全调控方法，将材料冶金、结构设计、制造工艺结合起来，统筹考虑服役结构的超高周疲劳失效问题，在抗疲劳设计时候同步考虑设计与制造的耦合效应，可以增强设计与制造的协同性，缩短设计与制造流程，有效提高材料与结构抗疲劳的能力，进而保障服役安全运维。
附图说明
本发明上述的以及其他的特征、性质和优势将通过下面结合附图和实施例的描述而变的更加明显，在附图中相同的附图标记始终表示相同的特征，其中：
图1揭示了根据本发明一实施例的基于设计/制造一体化的超长寿命服役结构抗疲劳及安全调控方法流程图；
图2揭示了根据本发明一实施例的超长寿命抗疲劳材料调控案例流程图；
图3揭示了根据本发明一实施例的超长寿命抗疲劳结构强度调控案例流程图；
图4揭示了根据本发明一实施例的超长寿命结构安全服役调控案例流程图。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅用以解释发明，并不用于限定发明。
研究发现，经历长寿命循环加载的结构多从内部缺陷处起裂，使内部缺陷致裂成为了结构超高周疲劳失效的典型特征。
可以认为，在已知内部微缺陷是超高周疲劳断裂的本质属性基础上，含缺陷材料的抗疲劳应该把焦点放在缺陷-基体的相互作用关系以及能影响这种关系的外部环境因素上。
内部缺陷的产生与材料冶金因素有关，而材料基体的性能取决于设计和制造工艺，环境因素代表着服役条件，三者的结合要求材料设计、冶金与制造工艺及服役环境的协调与统一。
超高周疲劳研究的最终目标是“寻求结构防断之法”，以保障结构的长寿命服役安全与可靠性。
基于上述分析，本发明提出的一种极端环境下超长寿命服役结构抗疲劳及安全调控方法，综合考虑材料强度、内部缺陷以及外部环境的影响，通过优化材料合金成分设计与冶金条件、结构制造工艺及服役条件等因素，建立“设计/制造一体化”的结构防断技术，进而实现服役结构的长寿命安全运维保障。
图1揭示了根据本发明一实施例的基于设计/制造一体化的超长寿命服役结构抗疲劳及安全调控方法流程图，如图1所示，本发明提出的一种极端环境下超长寿命服役结构抗疲劳及安全调控方法，包括以下步骤：
步骤S1、判断服役结构的长寿命阶段疲劳断裂模式，如果为内部缺陷致裂模式，则进入步骤S2；
步骤S2、根据缺陷-基体的交互作用原理，获得服役结构空气环境下超高周疲劳内部缺陷致裂机理；
步骤S3、考虑环境因素，明晰服役条件下超高周疲劳内部缺陷-基体-环境交互作用机理并获取环境削弱系数；
步骤S4、综合考虑环境因素，建立服役条件下的缺陷-载荷-寿命关联的超高周疲劳寿命预测理论模型；
步骤S5、根据超高周疲劳寿命预测理论模型，基于设计/制造一体化理念对材料冶金与制造工艺参数、结构强度设计参数、结构服役应力与环境参数进行调控。
本发明提供的基于设计/制造一体化的极端环境下超长寿命服役结构抗疲劳及安全调控方法及系统，在抗疲劳设计时同步考虑设计与制造的耦合效应，可以缩短设计与制造流程，有效提高材料与结构抗疲劳的能力。
作为共性基础技术，本方法体现着设计、制造和运维全寿命周期、一体化的防断调控路线，推动材料设计、冶金与制造工艺的兼容与协调，支撑系列高端装备超长寿命服役结构的防断设计、制造及其运行维护。
下文将对这些步骤进行详细描述。应理解，在本发明范围内，本发明的上述各技术特征和在下文(如实施例)中具体描述的各技术特征之间都可以互相组合，相互关联，从而构成优选的技术方案。
步骤S1、判断服役结构的长寿命阶段疲劳断裂模式，如果为内部缺陷致裂模式，则进入步骤S2。
更进一步的，如果为表面缺陷致裂模式，则根据传统抗疲劳理论模型进行抗疲劳及安全调控。
长寿命服役结构疲劳断裂模式分为表面缺陷致裂和内部缺陷致裂。
在步骤S1中对表面和内部致裂模式进行区分，如果是表面缺陷致裂模式，则按照传统抗疲劳理论模型进行抗疲劳设计，如果是内部缺陷致裂则进入步骤S2进行抗疲劳设计。
传统的抗疲劳理论模型主要包括低周疲劳Manson-Coffin模型和高周疲劳Basquin模型。
对于材料的疲劳损伤与寿命预测，经典的Basquin公式与Manson-Coffin公式分别选择应力幅与应变幅为参量进行评价。
Manson-Coffin模型是局部应力应变法中著名的应变-寿命关系式模型，用于对恒幅疲劳有限寿命进行直接预测，涉及的材料除了整体材料，还有焊接接头及新材料等，还扩展应用到短疲劳、变幅疲劳等。
Basquin模型用于描述疲劳寿命与应力之间的S-N曲线关系。
步骤S2、根据缺陷-基体的交互作用，获得服役结构空气环境下超高周疲劳内部缺陷致裂机理。
所述的基体-缺陷交互作用原理为循环载荷下缺陷周围局部塑性导致基体微观组织损伤。
步骤S3、考虑环境因素，明晰服役条件下超高周疲劳内部缺陷-基体-环境交互作用机理并获取环境削弱系数。
所述的缺陷-基体-环境的交互作用机理为循环载荷下缺陷周围局部塑性、化学元素与温度耦合作用导致基体微观组织损伤。
更进一步的，环境削弱系数H对应的表达式为：
Figure PCTCN2022119223-appb-000003
或
Figure PCTCN2022119223-appb-000004
σ (environment)为服役条件下的疲劳强度；
σ (air)为空气环境下的疲劳强度；
N (environment)为服役条件下的疲劳寿命；
N (air)为空气环境下的疲劳寿命。
步骤S4、综合考虑环境因素，建立服役环境下的缺陷-载荷-寿命关联的超高周疲劳寿命预测理论模型。
结合失效机理及环境削弱系数，基于内部微缺陷致裂机理的超高周疲劳寿命预测理论模型中综合考虑了内部微缺陷的几何尺寸、位置、形貌，基体性能影响因素和环境影响因素。
在本实施例中，超高周疲劳寿命预测理论模型，对应的表达式为：
{σ a(area) 1/12} αN f＝C
Z＝σ a(area) 1/6D β；
D＝(d-d inc)/d；
其中，σ a为疲劳应力幅；
area为微缺陷投影面积；
D为缺陷的相对位置；
α，C均为拟合常数；
N f为疲劳寿命；
β为材料常数；
d为疲劳试棒直径；
d inc为缺陷的中心点到试棒外侧表面的最小距离；
Z为疲劳寿命控制参量。
更具体的说，所述d inc可以是运用图像分析软件从疲劳断口扫描电镜照片上测量缺陷的中心点到试棒外侧表面的最小距离。
步骤S5、根据超高周疲劳寿命预测理论模型，基于设计/制造一体化的理念对材料冶金与制造工艺参数、结构强度设计参数、结构服役应力与环境参数进行调控。
所述步骤S5中，依据超高周疲劳寿命预测理论模型来调控材料冶金与制造工艺参数。
图2揭示了根据本发明一实施例的超长寿命抗疲劳材料调控案例流程图，如图2所示，步骤S5中根据超高周疲劳寿命预测理论模型，进行材料冶金与制造工艺参数调控，进一步包括以下步骤：
步骤S511、根据超高周疲劳寿命预测理论模型，调控冶金与制作工艺，进行材料设计和材料制造；
根据超高周疲劳寿命预测理论模型调控冶金与制造工艺，材料设计与制造的工艺参数均依据寿命预测理论模型来调控。
其中，材料设计包括强化基体和减小夹杂物尺寸，材料制造包括表面制造或内部制造。
步骤S512、对材料进行疲劳测试，对测试数据进行评估；
步骤S513、将评估结果与预期指标进行比较，如果评估结果满足预期指标要求，则当前材料为超长寿命抗疲劳材料，流程结束，如果评估结果不满足预期指标要求，则对冶金与制造工艺参数进行调控后重新进入步骤S511，直至评估结果满足预期指标要求。
所述步骤S5中，进一步依据超高周疲劳寿命预测理论模型，调控结构强度设计参数。
图3揭示了根据本发明一实施例的超长寿命抗疲劳结构强度调控案例流程，如图3所示，所述步骤S5中根据超高周疲劳寿命预测理论模型，进行结构强度设计参数调控，进一步包括以下步骤：
步骤S521、根据服役结构的长寿命阶段疲劳断裂模式进行结构疲劳设计和材料疲劳设计，获得结构强度设计参数；
所述的结构强度设计参数依据超长寿命抗疲劳材料性能来调控。
根据服役结构的长寿命阶段疲劳断裂模式(简称失效模式)进行结构强度设计。
对于表面缺陷致裂模式(表面失效)，进行结构疲劳设计；
对于内部缺陷致裂模式(内部失效)，进行材料疲劳设计；
最终，结构疲劳设计和材料疲劳设计所获得的疲劳设计参数统一作为结构强度设计参数。
步骤S522、基于超高周疲劳寿命预测理论模型对结构强度设计参数进行验证校核；
步骤S523、将验证校核结果与设计要求进行比较，如果验证校核结果满足设计要求，则当前结构强度设计参数为超长寿命抗疲劳设计参数，流程结束，如果验证校核结果不满足设计要求，则重新进入步骤S521，对结构强度设计参数进行调控，直至验证校核结果满足设计要求。
将超长寿命抗疲劳设计参数对应的设计模型作为超长寿命抗疲劳设计模型。
所述步骤S5中，进一步调控结构服役应力及环境参数，所述的结构服役应力及环境参数依据超长寿命抗疲劳材料及结构强度设计参数来调控。
图4揭示了根据本发明一实施例的超长寿命结构安全服役调控案例流程图，如图4所示，所述步骤S5中根据超高周疲劳寿命预测理论模型，进行结构服役应力与环境参数调控，进一步包括以下步骤：
步骤S531、将超高周疲劳寿命预测理论模型结合结构强度设计参数建立数字孪生模型；
服役应力与环境参数(以下简称服役参数)与上述步骤得到的超长寿命抗疲劳材料数据、失效机理等共同更新建立超高周疲劳寿命预测理论模型。
服役参数包括应力水平和环境参数。
根据建立的超高周疲劳寿命预测理论模型，结合结构强度设计参数来建立反映物理实体实时服役状态的数字模型，在本实施例中，该数字模型为数字孪生模型。
数字孪生是充分利用物理模型、传感器更新、运行历史等数据，集成多学科、多物理量、多尺度、多概率的仿真过程，在虚拟空间中完成映射，从而反映相对应的实体装备的全生命周期过程。
步骤S532、将数字孪生模型进行安全仿真分析；
在本实施例中，将数字孪生模型嵌入仿真软件进行安全仿真分析。
步骤S533、如果安全仿真输出结果为安全，则当前服役应力与环境参数符合要求，流程结束，如果安全仿真输出结果为不安全，则对服役应力与环境参数进行调控，重新进入步骤S531，直至安全仿真输出结果为安全，获得安全可靠的应力水平及环境参数。
尽管为使解释简单化将上述方法图示并描述为一系列动作，但是应理解并领会，这些方法不受动作的次序所限，因为根据一个或多个实施例，一些动作可按不同次序发生和/或与来自本文中图示和描述或本文中未图示和描述但本领域技术人员可以理解的其他动作并发地发生。
为使本申请实施的目的、技术方案和优点更加清楚，下面以电站汽轮机叶片抗疲劳设计为例，并结合本申请实施例中的附图，对本申请实施例中的技术方案进行更加详细的描述。
从失效分析案例中可以获得汽轮机叶片的损伤模式为典型的环境超高 周疲劳损伤，按照本发明公开的超长寿命服役结构抗疲劳及安全调控方法对汽轮机叶片进行抗疲劳设计，具体步骤如下：
步骤S1、确定汽轮机叶片的长寿命阶段疲劳断裂模式；
汽轮机叶片的长寿命阶段疲劳断裂模式包括表面缺陷致裂和内部缺陷致裂两种；
步骤S2、针对内部缺陷致裂模式，进一步确定汽轮机叶片超高周疲劳内部缺陷致裂机理；
根据缺陷-基体的交互作用原理，汽轮机叶片空气环境下的超高周疲劳内部缺陷致裂原理为循环载荷下缺陷周围局部塑性导致基体微观组织损伤。
步骤S3、考虑环境因素，明晰汽轮机叶片服役条件下超高周疲劳内部缺陷-基体-环境交互作用机理并获取环境削弱系数，获得汽轮机叶片服役条件(腐蚀环境)对超高周疲劳内部缺陷致裂机理的影响因素，并获取环境削弱系数；
因叶片在蒸汽或者盐水环境中服役，考虑环境影响，进一步表征发现缺陷周围存在大量的氢，所以环境的主要影响因素为氢的影响。
因此，叶片的超高周疲劳内部缺陷致裂机理需要考虑氢对缺陷周围基体微观组织疲劳损伤的影响。
步骤S4、综合考虑环境因素，考虑基体-缺陷-氢的影响，结合失效机理及环境削弱系数建立缺陷-载荷-寿命关联的超高周疲劳寿命预测理论模型。
在本实施例中，超高周疲劳寿命预测理论模型Z p，对应的表达式为：
{σ a(area) 1/12} αN f＝C
Z＝σ a(area) 1/6D β；
D＝(d-d inc)/d；
其中，σ a为疲劳应力幅，area为微缺陷投影面积，α，C均为拟合常数，N f为疲劳寿命，D为缺陷的相对位置，β为材料常数，受环境的影响，d为疲劳试棒直径，d inc为缺陷的中心点到试棒外侧表面的最小距离，Z为疲劳寿命控制参量。
步骤S5、根据超高周疲劳寿命预测理论模型，基于设计/制造一体化的理念对材料冶金与制造工艺参数、结构强度设计参数、结构服役应力与环境参数进行调控。
更具体的，步骤S5进一步包括以下步骤：
步骤S51、如图2所示，进行材料冶金与制造工艺参数的调控，获得超长寿命抗疲劳材料；
步骤S52、如图3所示，进行结构强度设计参数调控，获得超长寿命抗疲劳设计模型；
步骤S53、如图4所示，进行结构服役应力与环境参数调控，保障设计服役安全。
本发明提出的一种超长寿命服役结构抗疲劳及安全调控方法，将材料冶金、结构设计、制造工艺结合起来，统筹考虑服役结构的超高周疲劳失效问题，在抗疲劳设计时候同步考虑设计与制造的耦合效应，可以缩短设计与制造流程，有效提高材料与结构抗疲劳的能力，进而保障服役安全运维。
如本申请和权利要求书中所示，除非上下文明确提示例外情形，“一”、“一个”、“一种”和/或“该”等词并非特指单数，也可包括复数。一般说来，术语“包括”与“包含”仅提示包括已明确标识的步骤和元素，而这些步骤和元素不构成一个排它性的罗列，方法或者设备也可能包含其他的步骤或元素。
本领域技术人员将进一步领会，结合本文中所公开的实施例来描述的各种解说性逻辑板块、模块、电路和算法步骤可实现为电子硬件、计算机软件或这两者的组合。为清楚地解说硬件与软件的这一可互换性，各种解说性组件、框、模块、电路和步骤在上面是以其功能性的形式作一般化描述的。此类功能性是被实现为硬件还是软件取决于具体应用和施加于整体系统的设计约束。技术人员对于每种特定应用可用不同的方式来实现所描述的功能性，但这样的实现决策不应被解读成导致脱离了本发明的范围。
上述实施例是提供给熟悉本领域内的人员来实现或使用本发明的，熟悉本领域的人员可在不脱离本发明的发明思想的情况下，对上述实施例做出种种修改或变化，因而本发明的保护范围并不被上述实施例所限，而应该是符合权利要求书提到的创新性特征的最大范围。

Claims (10)

  1. 一种极端环境下超长寿命服役结构抗疲劳及安全调控方法，其特征在于，包括以下步骤：
    步骤S1、判断服役结构的长寿命阶段疲劳断裂模式，如果为内部缺陷致裂模式，则进入步骤S2；
    步骤S2、根据缺陷-基体的交互作用原理，获得服役结构空气环境下超高周疲劳内部缺陷致裂机理；
    步骤S3、考虑环境因素，明晰服役条件下超高周疲劳内部缺陷-基体-环境交互作用机理并获取环境削弱系数；
    步骤S4、综合考虑环境因素，建立服役条件下的缺陷-载荷-寿命关联的超高周疲劳寿命预测理论模型；
    步骤S5、根据超高周疲劳寿命预测理论模型，基于设计/制造一体化理念对材料冶金与制造工艺参数、结构强度设计参数、结构服役应力与环境参数进行调控。
  2. 根据权利要求1所述的极端环境下超长寿命服役结构抗疲劳及安全调控方法，其特征在于，所述步骤S1，进一步包括以下步骤：
    判断服役结构的长寿命阶段疲劳断裂模式，如果为表面缺陷致裂模式，则根据传统抗疲劳理论模型进行抗疲劳及安全调控。
  3. 根据权利要求2所述的极端环境下超长寿命服役结构抗疲劳及安全调控方法，其特征在于，所述传统抗疲劳理论模型包括低周疲劳Manson-Coffin模型和高周疲劳Basquin模型。
  4. 根据权利要求1所述的极端环境下超长寿命服役结构抗疲劳及安全调控方法，其特征在于，所述步骤S2的基体-缺陷交互作用原理为循环载荷下缺陷周围局部塑性导致基体微观组织损伤。
  5. 根据权利要求1所述的极端环境下超长寿命服役结构抗疲劳及安全调控方法，其特征在于，所述步骤S3的缺陷-基体-环境的交互作用机理为循环载荷下缺陷周围局部塑性、化学元素与温度耦合作用导致基体微观组织损伤。
  6. 根据权利要求1所述的极端环境下超长寿命服役结构抗疲劳及安全调控方法，其特征在于，所述步骤S3中的环境削弱系数H对应的表达式为：
    Figure PCTCN2022119223-appb-100001
    或
    Figure PCTCN2022119223-appb-100002
    σ (environment)为服役条件下的疲劳强度；
    σ (air)为空气环境下的疲劳强度；
    N (environment)为服役条件下的疲劳寿命；
    N (air)为空气环境下的疲劳寿命。
  7. 根据权利要求1所述的极端环境下超长寿命服役结构抗疲劳及安全调控方法，其特征在于，所述步骤S4的超高周疲劳寿命预测理论模型，对应的表达式为：
    {σ a(area) 1/12} αN f＝C
    Z＝σ a(area) 1/6D β；
    D＝(d-d inc)/d；
    其中，σ a为疲劳应力幅；
    area为微缺陷投影面积；
    D为缺陷的相对位置；
    α，C均为拟合常数；
    N f为疲劳寿命；
    β为材料常数；
    d为疲劳试棒直径；
    d inc为缺陷的中心点到试棒外侧表面的最小距离；
    Z为疲劳寿命控制参量。
  8. 根据权利要求1所述的极端环境下超长寿命服役结构抗疲劳及安全调控方法，其特征在于，所述步骤S5中根据超高周疲劳寿命预测理论模型，进行材料冶金与制造工艺参数调控，进一步包括以下步骤：
    步骤S511、根据超高周疲劳寿命预测理论模型，调控冶金与制作工艺，进行材料设计和材料制造；
    步骤S512、对材料进行疲劳测试，对测试数据进行评估；
    步骤S513、将评估结果与预期指标进行比较，如果评估结果满足预期指标要求，则当前材料为超长寿命抗疲劳材料，流程结束，如果评估结果不满足预期指标要求，则对冶金与制造工艺参数进行调控后重新进入步骤S511，直至评估结果满足预期指标要求。
  9. 根据权利要求1所述的极端环境下超长寿命服役结构抗疲劳及安全调控方法，其特征在于，所述步骤S5中根据超高周疲劳寿命预测理论模型，进行结构强度设计参数调控，进一步包括以下步骤：
    步骤S521、根据服役结构的长寿命阶段疲劳断裂模式进行结构疲劳设计和材料疲劳设计，获得结构强度设计参数；
    步骤S522、基于超高周疲劳寿命预测理论模型对结构强度设计参数进行验证校核；
    步骤S523、将验证校核结果与设计要求进行比较，如果验证校核结果满足设计要求，则当前结构强度设计参数为超长寿命抗疲劳设计参数，流程结束，如果验证校核结果不满足设计要求，则重新进入步骤S521，对结构强度设计参数进行调控，直至验证校核结果满足设计要求。
  10. 根据权利要求1所述的极端环境下超长寿命服役结构抗疲劳及安全调控方法，其特征在于，所述步骤S5中根据超高周疲劳寿命预测理论模型，进行结构服役应力与环境参数调控，进一步包括以下步骤：
    步骤S531、将超高周疲劳寿命预测理论模型结合结构强度设计参数建立数字孪生模型；
    步骤S532、将数字孪生模型进行安全仿真分析；
    步骤S533、如果安全仿真输出结果为安全，则当前服役应力与环境参数符合要求，流程结束，如果安全仿真输出结果为不安全，则对服役应力与环境参数进行调控，重新进入步骤S531，直至安全仿真输出结果为安全。
PCT/CN2022/119223 2022-09-16 2022-09-16 一种极端环境下超长寿命服役结构抗疲劳及安全调控方法 Ceased WO2024055271A1 (zh)

Priority Applications (3)

Application Number Priority Date Filing Date Title
PCT/CN2022/119223 WO2024055271A1 (zh) 2022-09-16 2022-09-16 一种极端环境下超长寿命服役结构抗疲劳及安全调控方法
CN202310143768.3A CN117113543A (zh) 2022-09-16 2023-02-20 一种极端环境下超长寿命服役结构抗疲劳及安全调控方法
US18/227,069 US20240104482A1 (en) 2022-09-16 2023-07-27 Anti-fatigue and safety control method for ultra-long life service structures under extreme environment

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/CN2022/119223 WO2024055271A1 (zh) 2022-09-16 2022-09-16 一种极端环境下超长寿命服役结构抗疲劳及安全调控方法

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US18/227,069 Continuation US20240104482A1 (en) 2022-09-16 2023-07-27 Anti-fatigue and safety control method for ultra-long life service structures under extreme environment

Publications (1)

Publication Number Publication Date
WO2024055271A1 true WO2024055271A1 (zh) 2024-03-21

Family

ID=88811637

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CN2022/119223 Ceased WO2024055271A1 (zh) 2022-09-16 2022-09-16 一种极端环境下超长寿命服役结构抗疲劳及安全调控方法

Country Status (3)

Country Link
US (1) US20240104482A1 (zh)
CN (1) CN117113543A (zh)
WO (1) WO2024055271A1 (zh)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN118465564A (zh) * 2024-07-11 2024-08-09 中国石油大学(华东) 一种固体氧化物燃料电池耐久性评估与服役寿命设计方法
CN119066985A (zh) * 2024-11-04 2024-12-03 浙江大学 基于逻辑约束强化符号回归的涡轮叶片疲劳寿命预测方法
CN119783452A (zh) * 2024-12-16 2025-04-08 霍尔科技(镇江)有限公司 一种压电阵列自适应振荡加速离位边缘烧蚀抑制方法及装置
CN120105622A (zh) * 2025-02-28 2025-06-06 重庆大学 聚酰胺酰亚胺复合涂层齿轮的设计制造方法

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN119168106B (zh) * 2024-04-19 2025-06-17 龙滩水电开发有限公司龙滩水力发电厂 基于全息感知的水电机组疲劳累积预测方法及系统
CN118569084A (zh) * 2024-06-04 2024-08-30 北京中鸿正霆科技有限公司 一种基于机器学习的部件寿命模拟测试方法及系统
CN118657038B (zh) * 2024-08-09 2024-10-18 长江三峡集团实业发展(北京)有限公司 抽水蓄能机组转轮的疲劳寿命评估方法、装置及设备
CN118886125B (zh) * 2024-09-29 2025-02-18 中国飞机强度研究所 一种飞机机身薄壁结构抗声疲劳形式确定方法及其系统
CN120275208A (zh) * 2025-04-09 2025-07-08 四川华电珙县发电有限公司 一种叶片材料的服役环境模拟装置及其应用方法
CN120874275B (zh) * 2025-07-18 2026-03-31 华东理工大学 面向装备本质安全的设计制造和服役全生命周期管理方法
CN121168082B (zh) * 2025-11-20 2026-02-17 武汉船舶通信研究所(中国船舶集团有限公司第七二二研究所) 基于修正模型的航空拖曳缆索使用寿命评估方法及系统

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108613889A (zh) * 2018-04-27 2018-10-02 佛山科学技术学院 一种基于循环寿命的钛合金钝缺口疲劳强度损失系数评估方法
CN110020497A (zh) * 2019-04-18 2019-07-16 长沙理工大学 服役桥梁吊索疲劳寿命概率评估方法
CN110069858A (zh) * 2019-04-23 2019-07-30 中国科学院金属研究所 一种金属材料不同温度条件下高周疲劳性能的预测方法
CN110609052A (zh) * 2019-08-26 2019-12-24 武汉钢铁有限公司 圆柱形金属材料的疲劳寿命预测方法、装置及电子设备
JP6944736B1 (ja) * 2021-01-08 2021-10-06 株式会社寿ホールディングス 疲労寿命予測方法、疲労寿命予測装置、疲労寿命予測プログラムおよび記憶媒体
CN113642192A (zh) * 2021-08-30 2021-11-12 北京理工大学 一种超高周疲劳寿命预测方法、装置及可存储介质
CN114282709A (zh) * 2021-11-26 2022-04-05 中国海洋大学 基于数字孪生的结构件疲劳裂纹扩展预测方法
CN115034578A (zh) * 2022-05-20 2022-09-09 中国电建集团华东勘测设计研究院有限公司 一种基于数字孪生的水工金属结构设备智能管理构建方法及系统

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108613889A (zh) * 2018-04-27 2018-10-02 佛山科学技术学院 一种基于循环寿命的钛合金钝缺口疲劳强度损失系数评估方法
CN110020497A (zh) * 2019-04-18 2019-07-16 长沙理工大学 服役桥梁吊索疲劳寿命概率评估方法
CN110069858A (zh) * 2019-04-23 2019-07-30 中国科学院金属研究所 一种金属材料不同温度条件下高周疲劳性能的预测方法
CN110609052A (zh) * 2019-08-26 2019-12-24 武汉钢铁有限公司 圆柱形金属材料的疲劳寿命预测方法、装置及电子设备
JP6944736B1 (ja) * 2021-01-08 2021-10-06 株式会社寿ホールディングス 疲労寿命予測方法、疲労寿命予測装置、疲労寿命予測プログラムおよび記憶媒体
CN113642192A (zh) * 2021-08-30 2021-11-12 北京理工大学 一种超高周疲劳寿命预测方法、装置及可存储介质
CN114282709A (zh) * 2021-11-26 2022-04-05 中国海洋大学 基于数字孪生的结构件疲劳裂纹扩展预测方法
CN115034578A (zh) * 2022-05-20 2022-09-09 中国电建集团华东勘测设计研究院有限公司 一种基于数字孪生的水工金属结构设备智能管理构建方法及系统

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN118465564A (zh) * 2024-07-11 2024-08-09 中国石油大学(华东) 一种固体氧化物燃料电池耐久性评估与服役寿命设计方法
CN119066985A (zh) * 2024-11-04 2024-12-03 浙江大学 基于逻辑约束强化符号回归的涡轮叶片疲劳寿命预测方法
CN119783452A (zh) * 2024-12-16 2025-04-08 霍尔科技(镇江)有限公司 一种压电阵列自适应振荡加速离位边缘烧蚀抑制方法及装置
CN120105622A (zh) * 2025-02-28 2025-06-06 重庆大学 聚酰胺酰亚胺复合涂层齿轮的设计制造方法

Also Published As

Publication number Publication date
CN117113543A (zh) 2023-11-24
US20240104482A1 (en) 2024-03-28

Similar Documents

Publication Publication Date Title
WO2024055271A1 (zh) 一种极端环境下超长寿命服役结构抗疲劳及安全调控方法
Yuan et al. Effect of mean stress and ratcheting strain on the low cycle fatigue behavior of a wrought 316LN stainless steel
CN112100766A (zh) 一种冷挤压强化孔结构的疲劳寿命预测方法
CN109255202B (zh) 一种用于机械构件疲劳裂纹萌生寿命的预估方法
CN114638130B (zh) 一种考虑激光冲击强化效果的疲劳寿命预测方法
CN115979804A (zh) 一种增材制造材料寿命预测方法
CN114912307B (zh) 一种镍基单晶高温合金的高周疲劳寿命预测方法
CN107449894B (zh) 氮化硅结合碳化硅耐火陶瓷的疲劳寿命预测方法
CN111024487A (zh) 一种基于晶粒尺寸及显微硬度的搅拌摩擦焊接头疲劳寿命预测方法
CN110806191B (zh) 基于应变监测的环焊缝缺陷管道安全评定方法
CN108627406A (zh) 一种基于损伤力学的高强金属材料变幅超高周疲劳寿命预测方法
WO2025086739A1 (zh) 一种不同强度金属材料在各平均应力下疲劳强度的预测方法
CN115855654B (zh) 一种综合评价结构材料力学性能的多参数图示方法
CN118445615A (zh) 一种基于显微组织损伤的高温合金长时蠕变寿命预测方法
CN120260762B (zh) 一种金属材料压缩蠕变本构模型构建方法
CN112129660A (zh) 一种喷丸处理后的搅拌摩擦焊接头疲劳寿命预测方法
CN1945269A (zh) 高温构件材料的寿命及寿命消耗的预测方法
CN119274710A (zh) 一种船用高强钢焊材的力学性能预测模型的构建方法、模型及预测方法
CN115203965B (zh) 一种通过迟滞回线预测纤维增强陶瓷基复合材料热残余应力和热残余应变的方法
CN118296933A (zh) 一种用于船舶结构的可信贝叶斯疲劳可靠性分析方法
CN117664239A (zh) 一种双相不锈钢热老化状况实时监测系统及方法
CN117473702A (zh) 一种预测增材制造金属材料疲劳失效起源类型的方法
CN108918690B (zh) 一种基于超声疲劳的铸造高温合金抗疲劳热等静压修复评定模型
CN114861358B (zh) 一种考虑表面完整性状态的轮盘模拟件设计方法
CN120087101B (zh) 考虑加工表面完整性的合金钢旋转弯曲疲劳寿命预测方法

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 22958462

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 22958462

Country of ref document: EP

Kind code of ref document: A1