CN111611680B - Manufacturing method of internal pressure steel elliptical head based on failure mode design - Google Patents
Manufacturing method of internal pressure steel elliptical head based on failure mode design Download PDFInfo
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- 238000013461 design Methods 0.000 title claims abstract description 53
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 25
- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 22
- 239000010959 steel Substances 0.000 title claims abstract description 22
- 239000000463 material Substances 0.000 claims abstract description 30
- 238000004364 calculation method Methods 0.000 claims abstract description 13
- 230000007797 corrosion Effects 0.000 claims abstract description 8
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- 239000010962 carbon steel Substances 0.000 claims description 2
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- 230000007547 defect Effects 0.000 abstract description 3
- 230000000694 effects Effects 0.000 abstract description 3
- 238000005482 strain hardening Methods 0.000 description 5
- 230000002706 hydrostatic effect Effects 0.000 description 4
- 230000008569 process Effects 0.000 description 4
- 238000012360 testing method Methods 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910001873 dinitrogen Inorganic materials 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 101100132433 Arabidopsis thaliana VIII-1 gene Proteins 0.000 description 1
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- 230000005489 elastic deformation Effects 0.000 description 1
- 239000013028 medium composition Substances 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000010200 validation analysis Methods 0.000 description 1
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- G—PHYSICS
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Abstract
The invention relates to the field of pressure vessels, and aims to provide a manufacturing method of an internal pressure steel elliptical head designed based on a failure mode. Comprising the following steps: determining the calculated pressure, and primarily selecting the size and the material of the seal head; determining the calculated thickness required for preventing the plastic collapse failure of the elliptical head; the calculated thickness of the elliptical head is rounded upwards to the thickness of the standard specification of the steel plate after the negative deviation of the thickness of the steel plate and the corrosion allowance are added, and the thickness is used as the nominal thickness of the elliptical head; and processing by using the nominal thickness of the seal head and the initially selected seal head size and material according to the specification of the manufacturing standard of the elliptical seal head by adopting a conventional manufacturing method to obtain an elliptical seal head product. The invention comprehensively considers two failure modes of buckling and plastic collapse of the internal pressure elliptical head, and makes up the defect that the existing standard lacks a design calculation formula for preventing the buckling failure of the elliptical head. Based on the elastoplasticity theory, the invention considers the spheroidization effect of the elliptical end socket, can reduce the wall thickness of the end socket, saves materials and has better economic benefit.
Description
Technical Field
The invention relates to the field of pressure containers, in particular to a manufacturing method of an internal pressure steel elliptical head based on failure mode design.
Background
The elliptical seal head is widely applied to various industries such as energy, chemical industry, food, pharmacy and the like, is an indispensable important basic component for pressure vessels such as various storage tanks, heat exchangers, reaction kettles, separators, containment vessels of nuclear power plants and the like, and has huge application quantity of the vessels subjected to internal pressure load. The mechanical behavior of the steel elliptical head is complex under the action of the internal pressure load, small elastic deformation occurs firstly, and then plastic deformation stage is carried out after yielding. Due to the strain hardening effect of the material and the structural characteristics of the elliptical head, the elliptical head deforms towards hemispherical shape along with the pressure rise, spheroidization occurs, and finally the head plastically collapses and fails, so that the bearing capacity is completely lost. In addition, because the elliptical end socket transition region is subjected to circumferential compressive stress, when the diameter-thickness ratio or the diameter-to-thickness ratio of the end socket is larger than a certain value, buckling failure occurs in the end socket transition region, and after the end socket is spheroidized, final plastic collapse failure occurs. Therefore, plastic collapse failure and buckling failure are two important failure modes to be considered when designing an internal pressure oval head.
Regarding the design method of the internal pressure elliptical head, the national standard GB/T150 adopts an elastic design criterion based on maximum stress, and the JB4732 adopts an ideal elastoplastic design concept based on limit load so as to prevent the elliptical head from plastic collapse failure. However, the design method for preventing the plastic collapse failure of the elliptical head by the two standards does not consider the influences of material strain hardening and head spheroidization. For buckling failure, the two standards only indicate that the end socket exceeding a sizing thickness ratio needs to be subjected to stability check, but no specific method guidance and specification are made, and the design and the manufacture of the ultra-large ultra-thin elliptic end socket are not facilitated. Although the U.S. specifications ASME PBVC VIII-1 and VIII-2 and European Union standard EN13445-3 both provide an internal pressure oval seal head design method based on failure modes, the design method for preventing plastic collapse failure is also based on elastic theory or ideal elastoplastic theory, and the influences of material strain hardening and seal head spheroidization are not considered. Research shows that the design method for preventing the plastic collapse failure of the internal pressure elliptic seal head based on the elastic theory or the ideal elastic-plastic theory gives out a design result which is too conservative and causes material waste because the influences of material strain hardening and seal head spheroidization are not considered. If the strain hardening and the spheroidization of the material can be considered, the bearing capacity of the elliptical seal head is fully utilized, the wall thickness of the elliptical seal head is reduced, the cost is saved, and the competitiveness of the product is improved.
Disclosure of Invention
The invention aims to solve the technical problem of overcoming the defects in the prior art and providing a manufacturing method of an internal pressure steel elliptical head designed based on a failure mode.
In order to solve the technical problems, the invention adopts the following solutions:
the manufacturing method of the internal pressure steel elliptical head based on failure mode design comprises the following steps:
(1) Determining the calculated pressure p according to the design condition of the pressure vessel c Preliminary selecting the inner diameter D of the seal head i Aspect ratio ofAnd the material used for the seal head, and determining the standard yield strength S of the material used for the seal head at the design temperature according to the pressure vessel standard y And allowable stress S m ；
(2) Determining a calculated thickness delta required to prevent plastic collapse failure of an elliptical head s ：
Wherein: delta s The unit mm is the calculated thickness required for preventing the plastic collapse failure of the elliptical head; p is p c For calculating the pressure, unit MPa; d (D) i The inner diameter of the elliptical end socket is in mm; s is S m The allowable stress of the material used for the seal head is expressed in MPa; alpha is an oval seal head calculation coefficient, and the value range is 0.27-0.45;
(3) If D i /δ s Less than or equal to 200, calculating the thickness delta according to the step (2) s The numerical value of (2) is used as the calculated thickness delta of the elliptical head, and the unit mm;
if D i /δ s If more than 200, the calculated thickness delta required for preventing the buckling failure of the elliptical end socket is determined according to the following formula b ：
Wherein: d (D) i The inner diameter of the elliptical end socket is in mm; p is p c For calculating the pressure, unit MPa; s is S y Standard yield strength of the material used for the seal head at the design temperature is expressed in MPa;is the diameter-to-height ratio of the end socket; beta is a reduction factor for a scoreAn elliptical seal head manufactured in a petal mode is adopted, and beta is 0.77; for an oval seal head manufactured by a stamping or spinning mode, beta is 1.0:
then, the calculated thickness delta required for preventing the plastic collapse failure is taken s And calculated thickness delta required to prevent buckling failure b The larger value of the two is used as the calculated thickness delta of the elliptical seal head, and the unit mm;
the calculated thickness of the elliptical head is rounded upwards to the thickness of the standard specification of the steel plate after the negative deviation of the thickness of the steel plate and the corrosion allowance are added, and the thickness is used as the nominal thickness of the elliptical head;
(4) And (3) processing the end socket nominal thickness obtained in the step (3) and the end socket size and the material selected in the step (1) by adopting a conventional manufacturing method according to the specification of an oval end socket manufacturing standard to obtain an oval end socket product.
In the step (2), the value range of the calculation coefficient alpha of the elliptical head is 0.27-0.30 for the elliptical head without the spliced welding joint.
In the invention, the diameter-thickness ratio of the elliptical headThe following should be satisfied: />
In the invention, the diameter-to-height ratio of the elliptical seal headThe following should be satisfied: />
In the invention, the material of the elliptical head is carbon steel, low alloy steel or high alloy steel which accords with the manufacturing standard of the pressure vessel.
In the present invention, the conventional manufacturing method in the step (4) includes a punching, spinning or split processing method.
Meter for measuringCalculating the pressure p c Is described in the following:
the pressure vessel design process generally begins with pressure vessel design conditions that include information such as vessel design criteria, operating pressure, operating temperature, media composition and characteristics. The present invention begins with the validation of pressure vessel design conditions. For pressure vessel design, there are working pressure, design pressure, and calculated pressure. The operating pressure refers to the highest pressure that can be reached at the top of the container under normal operating conditions. Design pressure: the highest pressure at the top of the container is set to a value not lower than the working pressure. Calculating the pressure: the pressure used to determine the thickness of the container element, i.e., the pressure in the calculation formula, includes additional loads such as hydrostatic pressure. Assuming that the operating pressure determined according to the process conditions is 10MPa, the design pressure may be set to 1.1 times the operating pressure, i.e., the design pressure is 11MPa. Without additional load, the calculated pressure may be 11MPa as the design pressure; if the hydrostatic pressure is 0.2MPa, the calculated pressure is 11.2MPa.
The calculated thickness of the elliptical head is rounded upwards to the thickness of the standard specification of the steel plate after the negative deviation of the thickness of the steel plate and the corrosion allowance are added, and the thickness is used as the nominal thickness of the elliptical head; the treatment process is within the skill of those skilled in the art, and therefore, the present invention is not described in detail.
Description of the inventive principles:
in the manufacturing method, the adopted oval seal head thickness calculation formula is obtained based on a prediction formula of the buckling pressure and the plastic collapse pressure of the oval seal head, and is verified by an industrial-scale oval seal head test result and is obtained by considering enough safety margin. Plastic collapse failure is a failure mode which inevitably occurs in an internal pressure oval seal head, and the calculated thickness required for preventing plastic collapse failure must be determined when designing oval seal heads with all dimensions. However, when the diameter-thickness ratio D of the elliptical end socket i /δ s When the thickness is more than 200, buckling failure of the seal head can also occur, at the moment, the calculated thickness required for preventing the two failure modes of plastic collapse failure and buckling failure is required to be determined simultaneously, and the larger value of the calculated thickness corresponding to the two failure modes is taken as the gauge of the elliptical seal headThe thickness is calculated, so that the plastic collapse failure is prevented, and the buckling failure is also prevented.
Compared with the prior art, the invention has the beneficial effects that:
1. the method comprehensively considers two failure modes of buckling and plastic collapse of the internal pressure elliptical head, and provides a head wall thickness calculation method for the two failure modes respectively, so that the defect that a design calculation formula for preventing the buckling failure of the elliptical head is lacking in the existing standard is overcome.
2. According to the wall thickness calculating method for preventing plastic collapse failure of the elliptical head, the spheroidization effect of the elliptical head is considered based on the elastoplasticity theory, so that the wall thickness of the head can be reduced, materials are saved, and economic benefits are better.
Drawings
Fig. 1 is a schematic cross-sectional view of an elliptical head.
Detailed Description
Specific example 1:
the implementation process of the present invention is described with reference to fig. 1 and specific example 1, and compared with the existing specification standard:
the oval head design conditions are shown in table 1:
TABLE 1 oval head design conditions
| Design pressure | 5MPa | Design temperature | 40℃ |
| Working medium | Nitrogen gas | Inner diameter of end socket | 600mm |
| Material | Q245R | Negative deviation C of thickness of steel plate 1 | 0.3mm |
| Corrosion margin C 2 | 0mm | Coefficient of weld joint | 1.0 |
(1) According to the design condition of the container, because the working medium is gas, the hydrostatic pressure does not need to be considered, and the calculated pressure is consistent with the design pressure, namely p c =5 MPa. Preliminary selection of the inner diameter D of the seal head i =600 mm and aspect ratioAnd the material Q245R for the seal head. Determining the yield strength S of a material Q245R used for the seal head at the design temperature of 40 ℃ according to the pressure vessel standard GB/T150.2 y =239 MPa and allowable stress S m ＝148MPa。
(2) Determining the calculated thickness required for preventing the plastic collapse failure of the elliptical head according to the following formula, wherein the head with the diameter of 600mm can be manufactured by adopting whole plate stamping without a spliced welding joint, and the calculation coefficient alpha of the elliptical head can be 0.27;
(3) Due to D i /δ s Calculated thickness δ=δ of elliptical head =109.ltoreq.200 s ＝5.5mm。
The calculated thickness of the oval head (delta=5.5 mm) is added to the negative deviation of the thickness of the steel plate (C 1 =0.3 mm) and corrosion margin (C 2 =0mm), the thickness of the steel plate standard specification is rounded up to be the nominal thickness of the elliptical head, i.e. the nominal thickness of the elliptical head is taken to be 6mm.
(4) And (3) processing the end socket nominal thickness obtained in the step (3) and the end socket size and the material selected in the step (1) by adopting a stamping manufacturing method according to the specification of an oval end socket manufacturing standard to obtain an oval end socket product.
The comparison of the calculated thickness of the elliptical head obtained by the method of the invention with the value obtained by the prior standard design method is shown in table 2.
Table 2 comparison of calculated thickness of elliptical heads for the inventive method and the existing canonical design method
| Method | GB/T 150 | JB 4732 | ASME VIII.1 | ASME VIII.2 | EN13445 | The method of the invention |
| Calculation of thickness/mm | 10.2 | 11.1 | 10.2 | 9.2 | 14.5 | 5.5 |
As can be seen from Table 2, the calculated thickness of the elliptical head obtained by the method of the invention can be reduced by more than 40% compared with the conventional standard design method, so that the wall thickness of the elliptical head product manufactured by the design of the invention is thinner, the cost is saved, and the competitiveness of the product is improved.
The design calculation data obtained by the method of the invention is used for manufacturing an elliptical end socket product, and the end socket product is subjected to a plastic collapse test, so that the plastic collapse pressure of the end socket is 16.9MPa, which is 3.4 times of the design pressure, and the elliptical end socket designed and manufactured by the method of the invention has enough safety margin.
Specific example 2:
the implementation process of the present invention will be described with reference to fig. 1 and specific example 2:
the oval head design conditions are shown in table 3:
TABLE 3 oval head design conditions
| Design pressure | 0.25MPa | Design temperature | 40℃ |
| Working medium | Nitrogen gas | Inner diameter of end socket | 1800mm |
| Material | S31603 | Negative deviation C of thickness of steel plate 1 | 0.3mm |
| Corrosion margin C 2 | 0mm | Coefficient of weld joint | 1.0 |
(1) According to the design condition, because the working medium is gas, the hydrostatic pressure does not need to be considered, and the calculated pressure is consistent with the design pressure, namely p c =0.25 MPa. Preliminary selection of the inner diameter D of the seal head i =1800 mm and aspect ratioAnd the material S31603 used for the seal head, and determining the yield strength S of the material S31603 used for the seal head at the design temperature of 40 ℃ according to the pressure vessel standard GB/T150.2 y =172 MPa and allowable stress S m ＝120MPa。
(2) The calculated thickness delta required for preventing the elliptical head from plastic collapse failure is determined according to the following formula s The stainless steel seal head with the diameter of 1800mm can be manufactured by stamping a whole plate with a spliced weld joint, and the calculation coefficient alpha of the elliptical seal head is 0.40;
(3) Due to D i /δ s If the ratio is more than 1200 and 200, the calculated thickness delta required for preventing the buckling failure of the elliptical head is determined according to the following formula b . The oval seal head is manufactured by stamping, and beta is 1.0.
Due to delta b ＞δ s Calculated thickness δ=δ of elliptical head b ＝2.4mm。
The calculated thickness of the oval head (delta=2.4 mm) is added to the negative deviation of the thickness of the steel plate (C 1 =0.3 mm) and corrosion margin (C 2 =0mm), the thickness of the steel plate standard specification is rounded up to be the nominal thickness of the elliptical head, i.e. the nominal thickness of the elliptical head is taken to be 3mm.
(4) And (3) processing the end socket nominal thickness obtained in the step (3) and the end socket size and the material selected in the step (1) by adopting a stamping manufacturing method according to the specification of an oval end socket manufacturing standard to obtain an oval end socket product.
The design calculation data obtained by the method of the invention is used for manufacturing an elliptical end socket product, and the end socket product is subjected to buckling test, so that the buckling pressure of the end socket is 1.43MPa and is 5.7 times of the design pressure, which indicates that the elliptical end socket designed and manufactured by the method of the invention still has enough safety margin.
Claims (6)
1. The manufacturing method of the internal pressure steel elliptical head based on the failure mode design is characterized by comprising the following steps of:
(1) Determining the calculated pressure p according to the design condition of the pressure vessel c Preliminary selecting the inner diameter D of the seal head i Aspect ratio ofAnd the material used for the seal head, and determining the standard yield strength S of the material used for the seal head at the design temperature according to the pressure vessel standard y And allowable stress S m ；
(2) Determining a calculated thickness delta required to prevent plastic collapse failure of an elliptical head s ：
Wherein: delta s The unit mm is the calculated thickness required for preventing the plastic collapse failure of the elliptical head; p is p c For calculating the pressure, unit MPa; d (D) i The inner diameter of the elliptical end socket is in mm; s is S m The allowable stress of the material used for the seal head is expressed in MPa; alpha is an oval seal head calculation coefficient, and the value range is 0.27-0.45;
(3) If D i /δ s Less than or equal to 200, calculating the thickness delta according to the step (2) s The numerical value of (2) is used as the calculated thickness delta of the elliptical head, and the unit mm;
if D i /δ s If more than 200, the calculated thickness delta required for preventing the buckling failure of the elliptical end socket is determined according to the following formula b ：
Wherein: d (D) i The inner diameter of the elliptical end socket is in mm; p is p c For calculating the pressure, unit MPa; s is S y Standard yield strength of the material used for the seal head at the design temperature is expressed in MPa;is the diameter-to-height ratio of the end socket; beta is a reduction factor, and for an elliptical end socket manufactured in a split mode, beta is 0.77; for an elliptical seal head manufactured in a stamping or spinning mode, beta is 1.0;
then, the calculated thickness delta required for preventing the plastic collapse failure is taken s And calculated thickness delta required to prevent buckling failure b The larger value of the two is used as the calculated thickness delta of the elliptical seal head, and the unit mm;
the calculated thickness of the elliptical head is rounded upwards to the thickness of the standard specification of the steel plate after the negative deviation of the thickness of the steel plate and the corrosion allowance are added, and the thickness is used as the nominal thickness of the elliptical head;
(4) And (3) processing the end socket nominal thickness obtained in the step (3) and the end socket size and the material selected in the step (1) by adopting a conventional manufacturing method according to the specification of an oval end socket manufacturing standard to obtain an oval end socket product.
2. The method according to claim 1, wherein in the step (2), the value of the calculated coefficient α of the elliptical head is in the range of 0.27 to 0.30 for the elliptical head without the splice joint.
3. The method of claim 1, wherein the elliptical head has a radial to thickness ratio ofThe following should be satisfied:
4. the method of claim 1, wherein the aspect ratio of the elliptical headThe following should be satisfied:
5. the method of claim 1, wherein the material of the elliptical head is carbon steel, low alloy steel, or high alloy steel that meets pressure vessel manufacturing standards.
6. The method of claim 1, wherein the conventional manufacturing method in step (4) comprises a stamping, spinning or split processing method.
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| CN103278375A (en) * | 2013-05-28 | 2013-09-04 | 浙江大学 | Manufacturing method of interior container of low-temperature container based on austenitic stainless steel low-temperature property |
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| CN110083922A (en) * | 2019-04-22 | 2019-08-02 | 浙江大学 | A method of preventing the failure of steel ellipsoidal head internal pressure buckling |
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| US20020077795A1 (en) * | 2000-09-21 | 2002-06-20 | Woods Joseph Thomas | System, method and storage medium for predicting impact performance of thermoplastic |
| CA2599755C (en) * | 2005-12-15 | 2015-03-31 | Jfe Steel Corporation | Local buckling performance evaluating method for steel pipe, steel pipe designing methiod, steel pipe manufacturing method, and steel pipe |
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| CN103278375A (en) * | 2013-05-28 | 2013-09-04 | 浙江大学 | Manufacturing method of interior container of low-temperature container based on austenitic stainless steel low-temperature property |
| CN109918835A (en) * | 2019-03-24 | 2019-06-21 | 北京化工大学 | A kind of binary criterion analysis design method for preventing plasticity from collapsing and being excessively plastically deformed |
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| 内压椭圆形封头设计方法比较研究;李克明;彭文珠;张泽坤;顾超华;徐平;工程设计学报(第001期);全文 * |
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