CN109799020B - Method capable of testing welding residual stress on manufacturing site - Google Patents
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Abstract
The invention provides a method capable of testing welding residual stress on a manufacturing site, which comprises the steps of welding a small welding joint sample, selecting a residual stress test point, drilling the small welding joint sample, measuring initial displacement before heat treatment, performing stress relief heat treatment after welding and measuring displacement after heat treatment, measuring the deformation conditions of the positions of drill holes before and after heat treatment by comparing the displacement of the drill holes before and after heat treatment, calculating the residual stress of the positions of the drill holes by deformation calculation of the positions of the drill holes, and calculating the welding residual stress of an actual structure to be tested on the manufacturing site by the residual stress of the positions of the drill holes. The method can fully utilize the convenient conditions of a manufacturing plant, can realize the residual stress test of the welding sample in the manufacturing site, can effectively avoid the waste of materials such as strain gauges and the like compared with the traditional method, avoids the trouble of operations such as strain pasting and the like, greatly simplifies the operation steps compared with the method for testing the internal residual stress of the material by neutron diffraction, and has convenient test and low cost.
Description
Technical Field
The invention relates to the technical field of residual stress testing, in particular to a method capable of testing welding residual stress on a manufacturing site.
Background
Welding is an important process in the manufacturing industry, and due to its highly concentrated instantaneous heat input, considerable weld residual stresses will develop after welding. The welding residual stress can seriously affect the manufacturing process and the service performance of the welding structure. Therefore, the accurate test of the welding residual stress has important significance for predicting and eliminating the welding residual stress of the actual structure.
The testing method of the welding residual stress can be divided into a mechanical measuring method and a physical measuring method. The mechanical measurement method is the residual stress test method which is the earliest developed and has the widest field application range, and the method is used for locally separating or cutting so as to locally release the residual stress, measuring the deformation before and after the division, and then applying the elastic mechanics knowledge to obtain the residual stress. Common mechanical measurements are borehole strain, ring-cut, etc. However, these methods require the application of strain gauges and can only measure the residual stress level of the surface or section. In order to understand the distribution of residual stress in the structure in detail, a method combining finite elements and tests is generally used for research. The method comprises the steps of firstly welding a small sample by adopting a welding process the same as that of a large structure, testing the residual stress distribution of the simple welding sample by adopting a test method, then simulating the residual stress distribution of the simple flat welding sample by adopting a thermal elastic plastic constitutive model, comparing the residual stress distribution with a test result, and analyzing the residual stress distribution with the corresponding large structure by adopting a verified finite element method.
At present, a residual stress test method for a small welding sample mainly comprises a drilling method, an X-ray method, an indentation method, a neutron diffraction method and the like, wherein a strain gauge is required to be adopted in the drilling method and the indentation method, the test method is expensive and consumes materials, and although the X-ray method and the neutron diffraction method do not need to consume materials, the test equipment is large, the test steps are complex, and the cost is high.
Therefore, it is necessary to develop a suitable low-cost and simple-to-test residual stress test method. At present, the residual stress test is not carried out on the welded product before the product leaves a factory. In order to provide reliable data for users, a series of residual stress tests need to be completed in a manufacturing plant, and the testing process is greatly convenient if the welding residual stress can be tested while manufacturing products by using the existing manufacturing conditions.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a method which is convenient to operate, low in cost and capable of testing the residual stress of a welding sample on a manufacturing site by fully utilizing the convenience conditions of a manufacturing factory.
The invention adopts the following technical scheme:
a method of enabling testing of weld residual stress at a manufacturing site, comprising the steps of:
(1) welding a small sample of a welding joint:
welding and processing a small welding joint sample according to a welding process for manufacturing a field actual structure to be measured, wherein the plate thickness of the small welding joint sample is consistent with that of the actual structure to be measured in the manufacturing field, and the small welding joint sample is fixed, so that the number of welding tracks, the number of layers, the welding current, the welding voltage and the welding speed of each welding track of the small welding joint sample and the actual structure to be measured in the manufacturing field are consistent;
(2) selecting a residual stress test point and drilling a small welding joint sample:
arranging residual stress test points according to the residual stress test requirements of a manufacturing site, arranging drilling positions at corresponding positions of the small welded joint samples according to the residual stress test points, and after the small welded joint samples are cooled to room temperature, drilling at the selected drilling positions by using an electric drilling machine, wherein the drilling depth is determined according to the positions of the residual stress test points in the plate thickness direction of the small welded joint samples;
(3) initial displacement measurement before heat treatment:
after drilling, measuring the initial displacement of the hole by using a coordinate measuring machine and taking the center of a welding seam of a small sample of the welded joint as an original point, and recording the displacement in the x direction before heat treatment as xiAnd the shift in the y-direction of the heat treatment front is denoted as yi；
The x direction is perpendicular to the welding seam, and the y direction is parallel to the welding seam;
(4) post-weld stress relief heat treatment:
heating the small welded joint sample to a heat treatment temperature in a heat treatment furnace according to a certain heating rate, preserving heat according to the heat treatment heat preservation time of a specified material, and then cooling to room temperature according to a certain cooling rate;
(5) displacement measurement after heat treatment:
moving the small welded joint sample after heat treatment out of the heat treatment furnace, cooling, measuring the displacement of the hole again by using a coordinate measuring machine with the center of the welded seam of the sample as an original point, and recording the displacement along the x direction (the direction perpendicular to the welded seam) after heat treatment as xfThe displacement in the y direction (direction parallel to the weld) after the heat treatment is denoted as yf；
(6) And measuring and obtaining the deformation conditions of the positions of the drill holes before and after the heat treatment by comparing the displacement of the drill holes before and after the heat treatment:
the deformations in the x direction (direction perpendicular to the weld) and the y direction (direction parallel to the weld) are calculated by the following equations (1) and (2), respectively:
in the formula, the first step is that,xandyrepresenting deformation in the x and y directions, respectively;
xidenotes the displacement of the heat treatment front in the x direction, xfDenotes the displacement in the x-direction after heat treatment, yiDenotes the displacement in the y direction of the heat treatment front, yfRepresents the displacement in the y direction after heat treatment;
(7) and calculating the residual stress of the drilling position through the deformation of the drilling position:
the residual stress of the drill hole position in the x direction (direction perpendicular to the weld) and the y direction (direction parallel to the weld) is calculated by the following formula (3) and formula (4), respectively:
σxand σyRepresenting stress in the x and y directions, respectively; e and upsilon represent the elastic modulus and Poisson's ratio, respectively;
and calculating the welding residual stress of the actual structure to be measured on the manufacturing site according to the residual stress of the drilling position.
Preferably, the diameter of the drilled hole drilled in the step (2) is 1-3 mm.
Preferably, the temperature rise rate, the heat treatment temperature, the holding time and the cooling rate of the post-weld heat treatment in the step (4) are obtained by inquiring criteria.
The invention has the beneficial effects that:
1. the method can make full use of the convenient conditions of a manufacturing plant, is convenient to operate and low in cost, and can realize the residual stress test of the welding sample on the manufacturing site.
2. Compared with the traditional method, the method can effectively avoid the waste of materials such as the strain gauge and the like, and avoid the trouble of operations such as strain pasting and the like.
3. The invention can test the residual stress distribution in the joint, and compared with the neutron diffraction test of the residual stress in the material, the operation steps are greatly simplified, and the test is convenient.
Drawings
FIG. 1 is a heat treatment process curve;
fig. 2 is a schematic diagram of a deformation test.
Wherein 1 is a welding seam; 2, drilling; 3 is a sample after heat treatment; 4 is a sample before heat treatment; Δ X is a displacement variation in a direction perpendicular to the weld; Δ Y is the amount of change in displacement in the direction parallel to the weld.
Detailed Description
The invention is described in detail below with reference to the accompanying drawings:
with reference to fig. 1 and 2, a method for testing welding residual stress in a manufacturing field includes the following steps:
(1) welding a small sample of a welding joint:
welding and processing a small welding joint sample according to a welding process for manufacturing a field actual structure to be measured, wherein the plate thickness of the small welding joint sample is consistent with that of the actual structure to be measured in the manufacturing field, and the small welding joint sample is fixed, so that the number of welding tracks, the number of layers, the welding current, the welding voltage and the welding speed of each welding track of the small welding joint sample and the actual structure to be measured in the manufacturing field are consistent;
(2) selecting a residual stress test point and drilling a small welding joint sample:
arranging residual stress test points according to the residual stress test requirements of a manufacturing site, arranging drilling positions at corresponding positions of the small welded joint samples according to the residual stress test points, after the small welded joint samples are cooled to room temperature, drilling at the selected drilling positions by using an electric drilling machine, wherein the drilling diameter is 1-3 mm, and the drilling depth is determined according to the positions of the residual stress test points in the plate thickness direction of the small welded joint samples; the drilling depth is accurately controlled by the drill bit fixing device, and when the drill bit does not move downwards any more, the electric drilling machine is turned off.
(3) Initial displacement measurement before heat treatment:
after drilling, measuring the initial displacement of the hole by using a coordinate measuring machine and taking the center of a welding seam of a small sample of the welded joint as an original point, and recording the displacement in the x direction before heat treatment as xiAnd the shift in the y-direction of the heat treatment front is denoted as yi；
The x direction is perpendicular to the welding seam, and the y direction is parallel to the welding seam;
(4) post-weld stress relief heat treatment:
heating the small welded joint sample to a heat treatment temperature in a heat treatment furnace according to a certain heating rate, preserving heat according to the heat treatment heat preservation time of a specified material, and then cooling to room temperature according to a certain cooling rate; the heating rate, the heat treatment temperature, the heat preservation time and the cooling rate of the postweld heat treatment are obtained through query standards.
(5) Displacement measurement after heat treatment:
moving the small welded joint sample after heat treatment out of the heat treatment furnace, cooling, measuring the displacement of the hole again by using a coordinate measuring machine with the center of the welded seam of the sample as an original point, and recording the displacement along the x direction (the direction perpendicular to the welded seam) after heat treatment as xfThe displacement in the y direction (direction parallel to the weld) after the heat treatment is denoted as yf；
(6) And measuring and obtaining the deformation conditions of the positions of the drill holes before and after the heat treatment by comparing the displacement of the drill holes before and after the heat treatment:
the deformations in the x direction (direction perpendicular to the weld) and the y direction (direction parallel to the weld) are calculated by the following equations (1) and (2), respectively:
in the formula, the first step is that,xandyrepresenting deformation in the x and y directions, respectively;
xidenotes the displacement of the heat treatment front in the x direction, xfDenotes the displacement in the x-direction after heat treatment, yiDenotes the displacement in the y direction of the heat treatment front, yfRepresents the displacement in the y direction after heat treatment;
(7) and calculating the residual stress of the drilling position through the deformation of the drilling position:
the residual stress of the drill hole position in the x direction (direction perpendicular to the weld) and the y direction (direction parallel to the weld) is calculated by the following formula (3) and formula (4), respectively:
σxand σyRepresenting stress in the x and y directions, respectively; e and upsilon represent the elastic modulus and Poisson's ratio, respectively;
and calculating the welding residual stress of the actual structure to be measured on the manufacturing site according to the residual stress of the drilling position.
Example 1
The adopted welding joint structure is as follows: manual arc welding, sample size length × width × height: 200X 20mm, Q345B material, V-groove. The heat treatment process employed in the method of the present invention is shown in fig. 2.
The magnitude of the residual stress at a depth of 4mm from the surface is shown in Table 1.
TABLE 1 residual stress at a depth of 4mm from the surface
Example 2
The adopted welding joint structure is as follows: manual arc welding, sample size length × width × height: 200X 30mm, the material is 304 stainless steel, X-shaped groove. The heat treatment process employed in the method of the present invention is shown in fig. 2.
The magnitude of the residual stress at a depth of 5mm from the surface is shown in Table 2.
TABLE 2 residual stress at a depth of 5mm from the surface
It is to be understood that the above description is not intended to limit the present invention, and the present invention is not limited to the above examples, and those skilled in the art may make modifications, alterations, additions or substitutions within the spirit and scope of the present invention.
Claims (2)
1. A method of enabling testing of weld residual stress at a manufacturing site, comprising the steps of:
(1) welding a small sample of a welding joint:
welding and processing a small welding joint sample according to a welding process for manufacturing a field actual structure to be measured, wherein the plate thickness of the small welding joint sample is consistent with that of the actual structure to be measured in the manufacturing field, and the small welding joint sample is fixed, so that the number of welding tracks, the number of layers, the welding current, the welding voltage and the welding speed of each welding track of the small welding joint sample and the actual structure to be measured in the manufacturing field are consistent;
(2) selecting a residual stress test point and drilling a small welding joint sample:
arranging residual stress test points according to the residual stress test requirements of a manufacturing site, arranging drilling positions at corresponding positions of the small welded joint samples according to the residual stress test points, after the small welded joint samples are cooled to room temperature, drilling at the selected drilling positions by using an electric drilling machine, wherein the drilling diameter is 1-3 mm, and the drilling depth is determined according to the positions of the residual stress test points in the plate thickness direction of the small welded joint samples;
(3) initial displacement measurement before heat treatment:
after drilling, measuring the initial displacement of the hole by using a coordinate measuring machine and taking the center of a welding seam of a small sample of the welded joint as an original point, and recording the displacement in the x direction before heat treatment as xiAnd the shift in the y-direction of the heat treatment front is denoted as yi；
The x direction is perpendicular to the welding seam, and the y direction is parallel to the welding seam;
(4) post-weld stress relief heat treatment:
heating the small welded joint sample to a heat treatment temperature in a heat treatment furnace according to a certain heating rate, preserving heat according to the heat treatment heat preservation time of a specified material, and then cooling to room temperature according to a certain cooling rate;
(5) displacement measurement after heat treatment:
moving the small welded joint sample after heat treatment out of the heat treatment furnace, cooling, measuring the displacement of the hole again by using a coordinate measuring machine with the center of the welded joint of the sample as an original point, and recording the displacement along the x direction after heat treatment as xfAnd the displacement in the y direction is denoted as yf；
(6) And measuring and obtaining the deformation conditions of the positions of the drill holes before and after the heat treatment by comparing the displacement of the drill holes before and after the heat treatment:
the deformation in the x-direction and the y-direction is calculated by the following formula (1) and formula (2), respectively:
in the formula, the first step is that,xandyrepresenting deformation in the x and y directions, respectively;
(7) and calculating the residual stress of the drilling position through the deformation of the drilling position:
the residual stress of the drill hole position in the x direction and the y direction is calculated by the following formula (3) and formula (4), respectively:
σxand σyRepresenting stress in the x and y directions, respectively; e and upsilon represent the elastic modulus and Poisson's ratio, respectively;
and calculating the welding residual stress of the actual structure to be measured on the manufacturing site according to the residual stress of the drilling position.
2. The method for testing the residual stress of the welding in the manufacturing field according to the claim 1, wherein the temperature rise rate, the heat treatment temperature, the holding time and the cooling rate of the post-welding heat treatment in the step (4) are obtained by inquiring the standard.
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