CN108664745B - Fatigue load equivalent conversion method for large-scale welded structural part - Google Patents
Fatigue load equivalent conversion method for large-scale welded structural part Download PDFInfo
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Abstract
The invention relates to a fatigue load equivalent transformation method for a large-scale welding structural part, which determines load information needing equivalent according to the operation condition of the large-scale welding structural part and relevant standards; calculating the stress concentration position and the stress state of the large-scale welding structural part under the action of theoretical load; combining a plurality of loads needing equivalent transformation into one load, and preliminarily determining the size and the direction of the equivalent load; determining the magnitude of the resultant moment of the load to be converted to the central point of the structural member, and calculating and determining the action position of the equivalent load; calculating the stress state of the original stress concentration position of the structural part; comparing fatigue lives of the same stress concentration positions determined by calculation in a fatigue equal life graph; and if the error result of the fatigue life of the stress concentration position before and after the equivalent transformation of the load meets the engineering requirement, determining the equivalent load of the structural member fatigue test. On the premise of ensuring that the fatigue life of the structural part is unchanged, the invention reduces the number of loads, simplifies the test scheme, saves the test cost and shortens the test period.
Description
Technical Field
The invention relates to a fatigue load test technology of a structural member, in particular to an equivalent transformation method of a fatigue load of a large-scale welded structural member.
Background
With the continuous development of mechanical equipment, the size of the mechanical equipment is larger and larger, the structure is more and more complex, and the functions are more and more complete. For the equipment with large size (the size in any direction is larger than 2m) and complex structure, the equipment cannot be prepared by the traditional machining means, and welding becomes the first choice for forming the mechanical structure by the characteristic of flexible operation, so that large complex structural parts are mostly welded structures, such as automobile frames, train bodies and the like which are used daily. And because the function requirement of the large-scale complicated structural part is higher, often can bear the effect of a plurality of different loads simultaneously, take the train automobile body as an example, when the train runs, the automobile body will bear the gravity, the traction force, the braking force, the horizontal backstop power and the like of the automobile body and passengers, wherein, the gravity is mainly and evenly distributed on the automobile body floor, the traction force and the braking force are mainly concentrated on the coupler seat and the center pin of the sleeper beam, and the horizontal backstop power is concentrated on the center pin of the sleeper beam.
For large welded structural members, welding defects are inevitable, local performance of welding materials is uneven, a welded heat affected zone can cause local deformation and residual stress is left, and hidden danger is hidden for safe service of the large welded structural members, so that before the large welded structural members leave factories and use, service safety of the large welded structural members needs to be evaluated, for example, before train bodies leave factories, fatigue performance of the large welded structural members needs to be evaluated according to European or Japanese standards.
At present, for service safety evaluation of large-scale welding structural parts, a whole vehicle is generally adopted for fatigue test, and the test period is long, equipment is complex and the cost is high. For the whole train, due to uneven stress distribution and different material properties of different parts, the parts of the whole train which are most prone to failure are often concentrated on certain parts of the whole train, for example, the parts which are relatively dangerous for the train body are body sleepers. Therefore, the safety evaluation of the dangerous parts can not only achieve the purpose of whole vehicle safety evaluation to a certain extent, but also greatly reduce the test cost and shorten the test period.
The safety evaluation of the dangerous component replaces the whole vehicle evaluation result, and the load of the whole vehicle needs to be reasonably converted to the dangerous component, so that the dangerous component always bears a plurality of load actions at the same time, and the action parts of the loads are likely to be concentrated at the same position, for example, three loads are obtained by a train sleeper beam from the whole vehicle conversion according to theoretical mechanics: transverse loads, longitudinal loads and air spring loads, and the transverse loads and the longitudinal loads act on different heights of the center pin simultaneously.
In the fatigue test of actual large-scale welded structure spare, the load is often applyed through hydraulic actuator, and when a plurality of loads were applyed simultaneously in a position, need a plurality of hydraulic actuator reasonable installation and cooperateing, can cause experimental complicacy like this, experimental cycle greatly prolonged, consequently if can utilize a load to replace the effect of a plurality of loads simultaneous actions, then can obviously improve the efficiency of this type of experiment.
At present, no technical scheme capable of solving the technical problems is reported.
Disclosure of Invention
Aiming at the defects of high test cost, long test period and the like of a large-scale welded structural part which simultaneously bears a plurality of loads in the prior art when a fatigue test is carried out, the invention aims to provide the fatigue load equivalent conversion method of the large-scale welded structural part, which can simplify the test scheme, save the test cost and shorten the test period.
In order to solve the technical problems, the invention adopts the technical scheme that:
the invention discloses a fatigue load equivalent transformation method for a large-scale welding structural part, which comprises the following steps of:
1) determining equivalent load information according to the operation condition and relevant standards of the large-scale welding structural part;
2) calculating the stress concentration position and the stress state of the large-scale welding structural part under the action of theoretical load by using a finite element method;
3) synthesizing a plurality of loads needing equivalent transformation into one load by using a force synthesis method, and preliminarily determining the size and the direction of the equivalent load;
4) determining the magnitude of the resultant moment of the load to be converted on the central point of the structural member by using a moment synthesis method, and calculating and determining the action position of the equivalent load by using the equivalent load preliminarily determined in the step 3);
5) under the action of the primary equivalent load, calculating the stress state of the original stress concentration position of the structural member through a finite element;
6) comparing the fatigue life of the same stress concentration position determined in the step 2) with the fatigue life of the same stress concentration position determined in the step 5) in the fatigue life map by using the fatigue life map, and judging the fatigue life error of the stress concentration position before and after the load equivalent transformation;
7) and 6) determining whether the error result of the fatigue life of the stress concentration position before and after the equivalent transformation of the load meets the engineering requirement, and if so, determining the equivalent load of the fatigue test of the structural member.
In the step 7), if the error result of the fatigue life of the stress concentration position before and after the load equivalent transformation does not meet the engineering requirement, the size of the equivalent load is adjusted, the stress state of the original stress concentration position on the structural member is recalculated, and then the judgment is carried out in the step 6).
When the size of the equivalent load is adjusted, the change range of the load adjusted for the first time is 20% of the original equivalent load, then the equivalent load is adjusted by utilizing a dichotomy search algorithm according to the comparison result of the step 6), wherein the fatigue life of the stress concentration position is in a negative correlation relation with the size of the equivalent load, the increase of the equivalent load reduces the fatigue life of the stress concentration position, and the decrease of the equivalent load increases the fatigue life of the stress concentration position.
Step 6), when determining and comparing the fatigue life of the stress concentration position by using a service life diagram of Goodman and the like, drawing the stress state of the stress concentration position obtained under the action of theoretical load in a coordinate system of the service life diagram of Goodman and the like, connecting the stress state with a coordinate point which represents the material strength limit on an abscissa and extending the coordinate point to an ordinate, wherein the straight line obtained in the way is the equal-life straight line of a certain stress concentration position; the stress state of the stress concentration position obtained under the action of the equivalent load is drawn into the same Goodman equal-life graph, and if the stress state is located on the determined equal-life straight line, the fatigue life of the same stress concentration position under the action of the two loads is the same; if the fatigue life of the stress concentration position is above the determined equal life straight line, the fatigue life of the stress concentration position is shorter than that of the theoretical load when the equivalent load acts; when the fatigue life of the stress concentration point is located below the determined equal life line, the fatigue life of the stress concentration point when the equivalent load is applied is longer than the fatigue life when the theoretical load is applied.
In step 6), comparing the fatigue life values of the 10 stress concentration positions determined in step 2) and step 5) by using a life map of Goodman and the like, regarding the large-sized welded structural member as a series system consisting of the 10 stress concentration positions, wherein any one stress concentration position has fatigue failure, the large-sized welded structural member fails, in other words, the shortest fatigue life is the fatigue life of the large-sized welded structural member in the 10 stress concentration positions; before and after the equivalent transformation of the load is compared, when the fatigue life error of the stress concentration position is compared, the stress concentration position with the shortest life can be used as a main reference, and other positions are used for auxiliary judgment, so that the error between the life value of the position under the action of the equivalent load and the fatigue life of the position under the action of the theoretical load is required to be less than 2%.
In the step 1), the information of the load needing to be equivalent comprises the number, the size, the direction and the acting position of the load.
The invention has the following beneficial effects and advantages:
1. aiming at the purpose of equivalently simplifying the fatigue load of a large-scale welded structure, the invention provides an equivalent transformation method for the fatigue load of the large-scale welded structure, which is a determination method for the fatigue test load of the large-scale welded structure bearing a plurality of loads at the same time.
2. The method of the invention obtains a fatigue test load which can replace a plurality of loads to act simultaneously by utilizing the force synthesis, the moment synthesis, the finite element method, the fatigue life and other life maps before and after the load conversion and on the premise of ensuring that the fatigue life of the large-scale welded structural part is basically unchanged.
Drawings
FIG. 1 is a flow chart of the method of the present invention;
FIG. 2 is a graphical representation of the load and restraint application patterns for stress calculations using a finite element method in accordance with the present invention;
FIG. 3 is a graphical representation of the location of stress concentration for equivalent load transfer in the method of the present invention;
FIG. 4 is a graphical representation of fatigue life of stress concentration locations calculated using the method of the present invention;
FIG. 5 is a graphical representation of a bolster fatigue test loading schedule obtained using the method of the present invention.
Fig. 6 is a diagram of a sleeper beam fatigue test of a subway train in a certain city by using the method of the invention.
Detailed Description
The invention is further elucidated with reference to the accompanying drawings.
The method of the invention obtains a fatigue test load which can replace a plurality of loads to act simultaneously by utilizing the force synthesis, the moment synthesis, the finite element method, the fatigue life and other life maps before and after ensuring the equivalent conversion of the load and the basically unchanged fatigue life of the large-scale welded structural member. The specific equivalent process can be briefly described as follows: firstly, determining load information of a large-scale welded structural part, analyzing the structural part by using a finite element method, and determining a stress concentration position; then, the theoretical equivalent load information is preliminarily determined by utilizing force synthesis and moment synthesis; and finally, evaluating the service life of the stress concentration position under the action of the equivalent load by using a finite element method and a fatigue life map, and adjusting for many times according to the service life of the stress concentration position until the fatigue life of the large-scale welded structural part is basically unchanged before and after the load equivalent transformation, so that the equivalent load used in the fatigue test can be obtained.
As shown in FIG. 1, the fatigue load equivalent transformation method for the large-scale welded structural part specifically comprises the following steps:
1) determining equivalent load information including the number, size, direction and action position of loads according to the operation condition and relevant standards of the large-scale welded structural part;
2) calculating the stress concentration position and the stress state of the large-scale welding structural part under the action of theoretical load by using a finite element method;
3) synthesizing a plurality of loads needing equivalent transformation into one load by using a force synthesis method, and preliminarily determining the size and the direction of the equivalent load;
4) determining the magnitude of the resultant moment of the load to be converted on the central point of the structural member by using a moment synthesis method, and calculating and determining the action position of the equivalent load by using the equivalent load preliminarily determined in the step 3);
5) under the action of the primary equivalent load, calculating the stress state of the original stress concentration position of the structural member through a finite element;
6) comparing the fatigue life of the same stress concentration position determined in the step 2) with the fatigue life of the same stress concentration position determined in the step 5) in the fatigue life map by using the fatigue life map, and judging the fatigue life error of the stress concentration position before and after the load equivalent transformation;
7) judging step 6) to determine whether the error result of the fatigue life of the stress concentration position before and after the equivalent transformation of the load meets the engineering requirement, and if so, determining the equivalent load of the fatigue test of the structural member;
and if the error result of the fatigue life of the stress concentration position before and after the load equivalent transformation does not meet the engineering requirement, adjusting the size of the equivalent load, recalculating the stress state of the original stress concentration position on the structural member, and then performing judgment in the step 6).
When the size of the equivalent load is adjusted, the change range of the load adjusted for the first time is 20% of the original equivalent load, then the equivalent load is adjusted by utilizing a dichotomy search algorithm according to the comparison result of the step 6), wherein the fatigue life of the stress concentration position is in a negative correlation relation with the size of the equivalent load, the increase of the equivalent load reduces the fatigue life of the stress concentration position, and the decrease of the equivalent load increases the fatigue life of the stress concentration position.
And 6) determining and comparing the fatigue life of the stress concentration position by using a service life diagram of Goodman and the like, based on the stress state of the stress concentration position obtained under the action of theoretical load, drawing the stress state in a coordinate system of the service life diagram of Goodman and the like, connecting the stress state with a coordinate point which represents the material strength limit on an abscissa and extending to an ordinate, wherein the straight line obtained in the way is the equal-life straight line of a certain stress concentration position. The stress state of the stress concentration position obtained under the action of the equivalent load is drawn into the same Goodman equal-life graph, and if the stress state is located on the determined equal-life straight line, the fatigue life of the same stress concentration position under the action of the two loads is the same; if the fatigue life of the stress concentration position is above the determined equal life straight line, the fatigue life of the stress concentration position is shorter than that of the theoretical load when the equivalent load acts; when the fatigue life of the stress concentration point is located below the determined equal life line, the fatigue life of the stress concentration point when the equivalent load is applied is longer than the fatigue life when the theoretical load is applied.
When the fatigue life values of the 10 stress concentration positions calculated and determined in the steps 2) and 5) are compared, the large-sized welded structural member can be regarded as a series system formed by the 10 stress concentration positions, any one stress concentration position has fatigue failure, the large-sized welded structural member fails, in other words, the shortest fatigue life among the 10 stress concentration positions is the fatigue life of the large-sized welded structural member. Before and after the equivalent transformation of the load is compared, when the fatigue life error of the stress concentration position is compared, the stress concentration position with the shortest life is taken as a main reference, and other positions are subjected to auxiliary judgment, so that the life value of the position under the action of the equivalent load is required to be slightly smaller than or equal to the fatigue life of the position under the action of the theoretical load.
In the embodiment, the fatigue load of the sleeper beam of a subway train in a certain city is equivalently converted into an example.
In the step 1), determining that the sleeper beam bears 4 fatigue loads (F) according to the train operation condition and relevant standardsa、FbRespectively longitudinal traction force, transverse stopping force, Fc、Fd,Is air spring load) and FaAnd FbRespectively has an action height of laAnd lb;
Step 2), calculating stress states of 10 stress concentration positions (10 numbers in fig. 3 are respectively stress concentration position labels) under the action of theoretical load by using a finite element method, and details are shown in step 6); the load and restraint application calculated using the finite element method is shown in fig. 2.
Step 3) force synthesis method is utilized to synthesize FaAnd FbAre combined to a load FhWhile determining FhThe direction of action of (c):
step 4), determining F by using a moment synthesis methodhHeight of action lh;
Step 5), performing preliminary calculation on F through finite elementshUnder the action of the stress state of 10 stress concentration positions in the step 2), the load and restraint applying mode at the moment are shown in figure 5;
step 6), comparing the fatigue life values of the 10 stress concentration positions determined in the step 2) and the step 5) by using a life map of Goodman and the like, and particularly showing in a figure 4;
step 7), as seen in step 6), in FhWhen the stress test device is used, the service life values of the 10 stress concentration positions are basically the same, and the service life value of the stress concentration position with the shortest service life is slightly lower than the fatigue life of the stress concentration position with the theoretical load, so that the requirement of slight conservation in engineering is met;
the error completely meets the engineering use requirement, the finally determined load scheme of the sleeper beam fatigue test is to act 3 fatigue loads, and the actual test is shown in figure 6.
The invention designs a method for determining the fatigue test load of a large welding structural member bearing a plurality of loads simultaneously, which reduces the number of loads, simplifies the test scheme, saves the test cost and shortens the test period on the premise of ensuring that the fatigue life of the structural member is basically unchanged.
Claims (6)
1. A fatigue load equivalent transformation method for a large-scale welded structural part is characterized by comprising the following steps:
1) determining equivalent load information according to the operation condition and relevant standards of the large-scale welding structural part;
2) calculating the stress concentration position and the stress state of the large-scale welding structural part under the action of theoretical load by using a finite element method;
3) synthesizing a plurality of loads needing equivalent transformation into one load by using a force synthesis method, and preliminarily determining the size and the direction of the equivalent load;
4) determining the magnitude of the resultant moment of the load to be converted on the central point of the structural member by using a moment synthesis method, and calculating the action position of the equivalent load by using the equivalent load preliminarily determined in the step 3);
5) under the action of the preliminarily determined equivalent load, calculating the stress state of the original stress concentration position of the structural member through a finite element;
6) comparing the fatigue life of the same stress concentration position determined in the step 2) with the fatigue life of the same stress concentration position determined in the step 5) in the fatigue life map by using the fatigue life map, and judging the fatigue life error of the stress concentration position before and after the load equivalent transformation;
7) and 6) determining whether the error result of the fatigue life of the stress concentration position before and after the equivalent transformation of the load meets the engineering requirement, and if so, determining the equivalent load of the fatigue test of the structural member.
2. The fatigue load equivalent transformation method for the large-scale welded structure according to claim 1, characterized in that: in the step 7), if the error result of the fatigue life of the stress concentration position before and after the load equivalent transformation does not meet the engineering requirement, the size of the equivalent load is adjusted, the stress state of the original stress concentration position on the structural member is recalculated, and then the judgment is carried out in the step 6).
3. The fatigue load equivalent transformation method for the large-scale welded structure according to claim 2, characterized in that: when the size of the equivalent load is adjusted, the change range of the load adjusted for the first time is 20% of the original equivalent load, then the equivalent load is adjusted by utilizing a dichotomy search algorithm according to the comparison result of the step 6), wherein the fatigue life of the stress concentration position is in a negative correlation relation with the size of the equivalent load, the increase of the equivalent load reduces the fatigue life of the stress concentration position, and the decrease of the equivalent load increases the fatigue life of the stress concentration position.
4. The fatigue load equivalent transformation method for the large-scale welded structure according to claim 1, characterized in that: step 6), when determining and comparing the fatigue life of the stress concentration position by using a service life diagram of Goodman and the like, drawing the stress state of the stress concentration position obtained under the action of theoretical load in a coordinate system of the service life diagram of Goodman and the like, connecting the stress state with a coordinate point which represents the material strength limit on an abscissa and extending the coordinate point to an ordinate, wherein the straight line obtained in the way is the equal-life straight line of a certain stress concentration position; the stress state of the stress concentration position obtained under the action of the equivalent load is drawn into the same Goodman equal-life graph, and if the stress state is located on the determined equal-life straight line, the fatigue life of the same stress concentration position under the action of the two loads is the same; if the fatigue life of the stress concentration position is above the determined equal life straight line, the fatigue life of the stress concentration position is shorter than that of the theoretical load when the equivalent load acts; when the fatigue life of the stress concentration point is located below the determined equal life line, the fatigue life of the stress concentration point when the equivalent load is applied is longer than the fatigue life when the theoretical load is applied.
5. The fatigue load equivalent transformation method for the large-scale welded structure according to claim 1, characterized in that: in step 6), comparing the fatigue life values of the 10 stress concentration positions determined in step 2) and step 5) by using a life map of Goodman and the like, regarding the large-sized welded structural member as a series system consisting of the 10 stress concentration positions, wherein any one stress concentration position has fatigue failure, the large-sized welded structural member fails, in other words, the shortest fatigue life is the fatigue life of the large-sized welded structural member in the 10 stress concentration positions; before and after the equivalent transformation of the load is compared, when the fatigue life error of the stress concentration position is compared, the stress concentration position with the shortest life can be used as a main reference, and other positions are used for auxiliary judgment, so that the error between the life value of the position under the action of the equivalent load and the fatigue life of the position under the action of the theoretical load is required to be less than 2%.
6. The fatigue load equivalent transformation method for the large-scale welded structure according to claim 1, characterized in that: in the step 1), the information of the load needing to be equivalent comprises the number, the size, the direction and the acting position of the load.
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CN113237749B (en) * | 2021-04-30 | 2024-05-03 | 中国航空工业集团公司西安飞机设计研究所 | Fatigue test design method based on serial multi-strut landing gear |
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