CN114528733B - Multi-point distributed heat source welding residual stress regulation and control method for steel bridge deck - Google Patents
Multi-point distributed heat source welding residual stress regulation and control method for steel bridge deck Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 62
- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 51
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- 230000033228 biological regulation Effects 0.000 title claims abstract description 35
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- 239000004033 plastic Substances 0.000 claims description 10
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- 238000010835 comparative analysis Methods 0.000 abstract 1
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- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 4
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Abstract
The invention relates to the technical field of welding residual stress heat treatment, in particular to a multipoint distributed heat source welding residual stress regulation and control method for a steel bridge deck, which comprises the steps of establishing a three-dimensional thermoplastic finite element model of the steel bridge deck, and then simulating a welding temperature field and a stress field according to an analysis result; transmitting the obtained theoretical heating temperature data to an intelligent data processing center; defining a main heating area and an auxiliary heating area according to the welding residual stress change conditions of different areas distant from the welding line; heating the main heating area and the auxiliary heating area by using oxyacetylene flame, and simultaneously performing real-time temperature measurement on the temperature measuring points to obtain real-time temperature data; the intelligent data processing center performs comparative analysis and regulation on theoretical heating temperature and real-time temperature data; the temperature of the material is increased to reduce the yield strength, and the residual stress is released, so that the aim of reducing or even residual tensile stress is fulfilled, and the rigidity, the strength, the stability and the fatigue life of the orthotropic steel bridge deck are ensured to be improved.
Description
Technical Field
The invention belongs to the technical field of welding residual stress heat treatment, and particularly relates to a multipoint distributed heat source welding residual stress regulating and controlling method for a steel bridge deck, which is suitable for purposefully regulating residual stress at different positions of a welding seam of the steel bridge deck.
Background
In recent years, a plurality of large-span steel structure bridges are built in China, orthotropic steel bridge decks become reasonable choices of modern bridges due to unique advantages of the orthotropic steel bridge decks, and the orthotropic steel bridge decks are successfully applied to large-span cable-stayed bridges and suspension bridges to form main bearing members of steel box girders and become an irreplaceable part of the steel box girders. But the orthotropic steel bridge deck has longitudinal ribs welded to the top plate, transverse partition plates welded to the top plate and longitudinal ribs welded to the transverse partition plates, and the welded base material is heated and melted fast to produce non-homogeneous plastic deformation to result in residual stress. The existence of the welding residual stress affects the safety and durability of the bridge. In order to release, weaken, avoid or eliminate the residual stress of welding as much as possible, we need to apply local flame heating to the tensile stress area according to the spatial distribution state of the residual stress of the steel bridge deck at different positions of each weld joint, and the yield strength of the heating area material is reduced along with the temperature rise, so that the residual stress is released, and the residual tensile stress is reduced or even, so as to ensure that the rigidity, strength, stability and fatigue life of the orthotropic steel bridge deck are improved.
In order to improve the fatigue performance of the welded joint, various process treatment methods are proposed at present: annealing, local heating, TIG welding remelting, laser cladding, overload, shot blasting, hammering, grinding, etc. Expert scholars at home and abroad have conducted extensive researches on the local heat treatment technology, and local heating sources are adopted in the modes of flame, electric heating, induction heating and the like. The method for regulating and controlling the residual welding stress of the multipoint distributed heat source adopts a local heating method, and the local heating source is a plurality of groups of oxyacetylene flames with moving travelling mechanisms, so that the same temperature can be applied to a required heating area in a large-area and high-efficiency manner, and the temperature has uniformity. As it forms a movable heating belt, and the temperature can be controlled and regulated, flexibly controlled, etc.
Disclosure of Invention
The invention provides a multipoint distributed heat source welding residual stress regulating and controlling method for a steel bridge deck, which aims to solve the technical problems in the prior art, analyzes the spatial distribution state of the node residual stress of the steel bridge deck by combining a numerical simulation calculation means, and then applies local oxyacetylene flame heating to a tensile stress area in a targeted manner, wherein the yield strength of the material is reduced by heating area materials along with temperature elevation, and the residual stress is released, so that the residual tensile stress is reduced or even, the rigidity, the strength, the stability and the fatigue life of the orthotropic steel bridge deck are improved, and the safety guarantee is provided for the normal operation of an in-service bridge.
In order to achieve the above purpose, the invention adopts the following technical scheme:
a multipoint distributed heat source welding residual stress regulation method for a steel bridge deck comprises the following steps:
step1: carrying out surface pretreatment on the steel bridge deck, removing residual oxides on the surface of the steel bridge deck, removing surface grease and pollutants by using solutions such as acetone and the like, ensuring the flatness of the surface to be adhered, and collecting welding parameters of the steel bridge deck;
step2: according to the collected welding parameters of the steel bridge deck, a three-dimensional thermal elastic plastic finite element model of the steel bridge deck is built, then a welding temperature field and a stress field are simulated according to an analysis result, and the obtained theoretical heating temperature data are transmitted to an intelligent data processing center through a WiFi network;
step3: preliminarily determining the distribution characteristics of the welding residual stress of the steel bridge deck plate through welding stress field simulation, obtaining the welding residual stress change conditions of different areas apart from welding seams, defining different heat source regulation areas and making marks;
step4: further refining a heat source regulation and control region, combining numerical simulation to determine a main heating region and an auxiliary heating region, wherein the main heating region is positioned at a position which is 0.6 t-1.2 t close to the welding seam region, t is the thickness of a base material, the auxiliary heating region is positioned at a position which is 2 t-4 t far from the welding seam region, and the range of the main heating region and the range of the auxiliary heating region are adjusted according to actual conditions;
step5: adopting a plurality of groups of oxyacetylene flames with moving travelling mechanisms, carrying out heating treatment on the main heating area and the auxiliary heating area according to set heat source regulation and control parameters, and simultaneously adopting an infrared thermometer to monitor the temperature of the regulation and control area in real time to obtain real-time temperature data;
step6: the intelligent data processing center compares the theoretical heating temperature of step2 with real-time temperature data of step5, and analyzes whether the result is within a specified error range;
step7: after one round of heat source regulation is completed, the main heating area and the auxiliary heating area of the steel bridge deck are subjected to heat preservation treatment, so that the temperature of the regulation area is ensured to be slowly reduced;
step8: and detecting residual stress of the key part after regulation by adopting an X-ray diffractometer, evaluating whether the regulation requirement is met, if not, updating the heat source regulation parameters, and returning to step3 to start a new round of heat source regulation.
As a preferable technical scheme, the temperature field in step2 belongs to standard three-dimensional nonlinear unsteady heat conduction, and a three-dimensional heat conduction control equation of the welding process is as follows:
wherein ρ is the material density (kg×m) -3 ) The method comprises the steps of carrying out a first treatment on the surface of the c is the specific heat capacity (j/(kg x k)) of the material; λ is the thermal conductivity of the material (W/(m×k)); t is the heat transfer time(s); t is a temperature field distribution function;to solve for the intensity (W/m) of the internal heat source in the region 3 ) The method comprises the steps of carrying out a first treatment on the surface of the Where ρ, c, λ are all functions of temperature T.
As a preferable technical solution, in the numerical simulation of the temperature field in step2, the following formula is adopted to calculate, and if the space domain Ω is scattered into a limited number of unit bodies, the temperature T of a certain unit can be approximately calculated by the node temperature T i Interpolation results, namely: t=nt e ；
Wherein N is an interpolation function, namely a shape function; t (T) e Is a time-dependent node temperature vector; t is a node temperature vector; k is a heat conduction matrix; c is a heat capacity matrix; p is the temperature load column vector; K. c, P are all temperature dependent variables;
as a preferred technical solution, the welding stress field simulation in step3 is calculated by the following formula:
dε＝dε e +dε p +dε T
dσ＝Ddε-CdT
wherein dε is the strain increase caused by temperature change; dε e Is an elastic strain increment; dε T Is the strain increment caused by temperature; d is a thermoplastic matrix; c is a vector related to temperature; dε e Is the plastic strain increment;is equivalent strain increment; dε 0 Stress increment caused by temperature change; d (D) e Is an elastic matrix.
As a preferable technical scheme, the method for determining the main heating area and the auxiliary heating area in step4 comprises the following steps: setting a region at a position 0.8 t-1.2 t away from the U-rib-cover plate joint weld joint as a first main heating region, and setting a region at a position 2 t-4 t away from the U-rib-cover plate joint weld joint as a first auxiliary heating region; setting the area at the position 0.8 t-1.2 t away from the joint weld of the cover plate-U rib-diaphragm plate as a second main heating area and the area at the position 2 t-4 t away from the joint weld of the cover plate-U rib-diaphragm plate as a second auxiliary heating area; wherein t is the thickness of the weld joint parent metal, and temperature measuring points are arranged at the same time.
As a preferred technical solution, the welding residual stress of the first main heating zone, the first auxiliary heating zone, the second main heating zone, and the second auxiliary heating zone in step5 may be calculated by the following formula:
Δε＝Δε T +Δε ΔV +Δε trip ；
Δε T ＝α(T)ΔT；
f M ＝1-EXP[-(M S -)]；
wherein: delta epsilon is the welding residual stress field; delta epsilon T Is a thermoelastic strain; delta epsilon ΔV Is the volume strain; delta epsilon trip Is a phase change plastic strain; f (f) A And f M Respectively austenite volume fraction and martensite volume fraction, T is the current temperature, A C1 For the austenite transformation temperature, A C3 For the austenite transformation end temperature, A and D are the material-related coefficients, M S Is the martensite transformation temperature, C is the material constant, Δf K The volume fraction of the K phase is the volume strain when the phase is completely changed, K is a trip coefficient, S is a bias stress, and ζ is a phase change rate; α (T) is the temperature-dependent linear expansion coefficient, Δt is the temperature variation amplitude, and f' (ζ) is the derivative of the saturation function.
As a preferable technical scheme, if the error requirement within 5% is met, heating the first main heating area and the second main heating area to the heat preservation temperature, heating the corresponding auxiliary heating areas when the main heating area starts to be cooled, and cooling the auxiliary heating areas after the main heating area is cooled to a certain temperature; if the error requirement within 5% is not met, the temperature of the oxyacetylene flame is adjusted, and the oxyacetylene flame is reapplied until the error requirement within 5% is met.
The invention has the advantages and positive effects that:
according to the method, the spatial distribution state of the residual stress of the node is calculated by combining a finite element numerical simulation calculation means, then a local heat source is applied to a tensile stress area in a targeted manner for heating, the yield strength of the material is reduced along with the temperature rise of a heating area material, the residual stress is released, and therefore the residual tensile stress is reduced or even, the rigidity, the strength, the stability and the fatigue life of the orthotropic steel bridge deck are improved, and the safety guarantee is provided for the normal operation of an in-service bridge.
Description of the drawings:
FIG. 1 is a system diagram of the present invention;
FIG. 2 is a schematic diagram of the regulation of residual stress of the weld joint of the U-rib-cover plate joint according to the invention;
FIG. 3 is a schematic diagram of the regulation of residual stress of the weld joint of the cover plate-U rib-diaphragm plate joint of the present invention;
FIG. 4 is a step diagram of the present invention;
fig. 5 is a flow chart of the present invention.
In the figure, 1, U rib-cover plate; 11. a first main heating zone; 12. a first secondary heating zone; 2. cover plate-U rib-diaphragm plate; 21. a second main heating zone; 22. a second subsidiary heating zone; 3. oxy-acetylene flame; 4. an intelligent data processing center; 5. an infrared thermometer; 6. an X-ray diffractometer.
Detailed Description
The drawings in the embodiments of the present invention will be combined; the technical scheme in the embodiment of the invention is clearly and completely described; obviously; the described embodiments are only a few embodiments of the present invention; but not all embodiments. Based on the embodiments in the present invention; all other embodiments obtained by those skilled in the art without undue burden; all falling within the scope of the present invention.
As shown in fig. 1 to 5, the invention provides a method for regulating and controlling residual stress of multi-point distributed heat source welding for a steel bridge deck, which comprises the following steps:
step1: carrying out surface pretreatment on the steel bridge deck, removing residual oxides on the surface of the steel bridge deck by adopting modes such as manual treatment, mechanical treatment and the like, removing surface grease and pollutants by using solutions such as acetone and the like, ensuring the flatness of the surface to be pasted, and collecting welding parameters of the steel bridge deck;
step2: according to the collected welding parameters of the steel bridge deck, a three-dimensional thermal elastic plastic finite element model of the steel bridge deck is built, and the building conditions of the finite elements comprise: geometric model, material thermophysical and mechanical parameters, welding heat source, unit selection, grid division, boundary conditions and the like, and then performing welding temperature field and stress field simulation according to the analysis results; the obtained theoretical heating temperature data are transmitted to the intelligent data processing center 4 through a WiFi network;
because the temperature field belongs to standard three-dimensional nonlinear unsteady heat conduction, the three-dimensional heat conduction control equation of the welding process is as follows:
wherein ρ is the material density (kg×m) -3 ) The method comprises the steps of carrying out a first treatment on the surface of the c is the specific heat capacity (j/(kg x k)) of the material; λ is the thermal conductivity of the material (W/(m×k)); t is the heat transfer time(s); t is a temperature field distribution function;to solve for the intensity (W/m) of the internal heat source in the region 3 ) The method comprises the steps of carrying out a first treatment on the surface of the Where ρ, c, λ are all functions of temperature T.
In the numerical simulation of the temperature field, the following formula is adopted to calculate, if the space domain omega is scattered into a limited unit body, the temperature T of a certain unit can be approximatedThrough the node temperature T i Interpolation results, namely:
T＝NT e ；
wherein N is an interpolation function, namely a shape function; t (T) e Is a time-dependent node temperature vector; t is a node temperature vector; k is a heat conduction matrix; c is a heat capacity matrix; p is the temperature load column vector; K. c, P are all temperature dependent variables;
step3: preliminarily determining the distribution characteristics of the welding residual stress of the steel bridge deck plate through stress field simulation, obtaining the welding residual stress change conditions of different areas apart from the welding line, defining different heat source regulation areas and making marks;
the stress field simulation is realized by carrying out welding elastoplastic finite element analysis on the basis of the established steel bridge deck finite element model; in performing the welding stress field simulation, the following formula is adopted for calculation:
dε＝dε e +dε p +dε T
dσ＝Ddε-CdT
wherein dε is the strain increase caused by temperature change; dε e Is an elastic strain increment; dε T Is the strain increment caused by temperature; d is a thermoplastic matrix; c is a vector related to temperature; dε e Is the plastic strain increment;is equivalent strain increment; dε 0 Stress increment caused by temperature change; d (D) e Is an elastic matrix;
step4: further refining the heat source regulation and control region, and determining a main heating region and an auxiliary heating region by combining numerical simulation: the area which is 0.8t to 1.2t away from the U-rib-cover plate joint weld joint is set as a first main heating area 11, and the area which is 2t to 4t away from the U-rib-cover plate joint weld joint is set as a first auxiliary heating area 12; the area which is 0.8t to 1.2t away from the joint weld joint of the cover plate-U rib-diaphragm plate is set as a second main heating area 21, and the area which is 2t to 4t away from the joint weld joint of the cover plate-U rib-diaphragm plate is set as a second auxiliary heating area 22; wherein t is the thickness of the weld joint parent metal, and temperature measuring points are arranged at the same time; the welding residual stress of the first main heating zone 11, the first sub heating zone 12, the second main heating zone 21, and the second sub heating zone 22 can be calculated by the following formula:
Δε＝Δε T +Δε ΔV +Δε trip ；
Δε T ＝α(T)ΔT；
f M ＝1-EXP[-(M S- )]；
wherein: delta epsilon is the welding residual stress field; delta epsilon T Is a thermoelastic strain; delta epsilon ΔV Is the volume strain; delta epsilon trip Is a phase change plastic strain; f (f) A And f M Respectively austenite volume fraction and martensite volume fraction, T is the current temperature, A C1 For the austenite transformation temperature, A C3 For the austenite transformation end temperature, A and D are the material-related coefficients, M S Is the martensite transformation temperature, C is the material constant, Δf K The volume fraction of the K phase is the volume strain when the phase is completely changed, K is a trip coefficient, S is a bias stress, and ζ is a phase change rate; alpha (T) is the linear expansion coefficient related to temperature, delta T is the temperature variation amplitude, and f' (ζ) is the derivative of the saturation function;
step5: adopting a plurality of groups of oxyacetylene flames with moving travelling mechanisms, carrying out heating treatment on the first main heating zone 11, the first auxiliary heating zone 12, the second main heating zone 21 and the second auxiliary heating zone 22 according to set heat source regulation and control parameters, and simultaneously carrying out real-time temperature measurement treatment on the temperature measurement points by using an infrared thermometer 5 to obtain real-time temperature data;
step6: the intelligent data processing center compares the theoretical heating temperature of step2 with real-time temperature data of step5, and whether an analysis result is within a specified error range of 5%;
if the error requirement within 5% is met, heating the first main heating area and the second main heating area to the heat preservation temperature, heating the corresponding auxiliary heating areas when the main heating area starts to cool down, and starting to cool down the auxiliary heating areas after the main heating area is cooled down to a certain temperature;
if the error requirement within 5% is not met, adjusting the temperature of the oxyacetylene flame, and reapplying the oxyacetylene flame 3 until the error requirement within 5% is met;
step7: after one round of heat source regulation is completed, the main heating area and the auxiliary heating area of the steel bridge deck are subjected to heat preservation treatment, so that the temperature of the regulation area is ensured to be slowly reduced;
step8: and detecting residual stress of the key part after regulation by adopting an X-ray diffractometer, evaluating whether the regulation requirement is met, if not, updating the heat source regulation parameters, and returning to step3 to start a new round of heat source regulation.
The foregoing describes the embodiments of the present invention in detail, but the description is only a preferred embodiment of the present invention and is not to be construed as limiting the scope of the invention. All equivalent changes and modifications within the scope of the present invention are intended to be covered by the present invention.
Claims (7)
1. The multi-point distributed heat source welding residual stress regulation and control method for the steel bridge deck is characterized by comprising the following steps of:
step1: carrying out surface pretreatment on the steel bridge deck, removing residual oxides, surface grease and pollutants on the surface of the steel bridge deck, ensuring the flatness of the surface to be pasted, and collecting welding parameters of the steel bridge deck;
step2: according to the collected welding parameters of the steel bridge deck, a three-dimensional thermal elastic plastic finite element model of the steel bridge deck is built, then welding temperature field simulation is carried out according to analysis results, and obtained theoretical heating temperature data are transmitted to an intelligent data processing center through a WiFi network;
step3: preliminarily determining the distribution characteristics of the welding residual stress of the steel bridge deck plate through welding stress field simulation, obtaining the welding residual stress change conditions of different areas apart from welding seams, defining different heat source regulation areas and making marks;
step4: further refining a heat source regulation and control region, combining numerical simulation to determine a main heating region and an auxiliary heating region, wherein the main heating region is positioned at a position which is 0.6 t-1.2 t close to the welding seam region, t is the thickness of a base material, the auxiliary heating region is positioned at a position which is 2 t-4 t far from the welding seam region, and the range of the main heating region and the range of the auxiliary heating region are adjusted according to actual conditions;
step5: heating the main heating area and the auxiliary heating area by using oxyacetylene flame, and simultaneously performing real-time temperature measurement on the temperature measuring points by using an infrared thermometer to obtain real-time temperature data;
step6: the intelligent data processing center compares the theoretical heating temperature of step2 with real-time temperature data of step5, and analyzes whether the result is within a specified error range;
step7: after one round of heat source regulation is completed, the main heating area and the auxiliary heating area of the steel bridge deck are subjected to heat preservation treatment, so that the temperature of the regulation area is ensured to be slowly reduced;
step8: and detecting residual stress of the key part after regulation by adopting an X-ray diffractometer, evaluating whether the regulation requirement is met, if not, updating the heat source regulation parameters, and returning to step3 to start a new round of heat source regulation.
2. The method for controlling residual stress in welding a multi-point distributed heat source for a steel bridge deck according to claim 1, wherein the temperature field in step2 belongs to standard three-dimensional nonlinear unsteady state heat conduction, and the three-dimensional heat conduction control equation of the welding process is:
wherein ρ is the material density (kg×m) -3 ) The method comprises the steps of carrying out a first treatment on the surface of the c is the specific heat capacity (j/(kg x k)) of the material; λ is the thermal conductivity of the material (W/(m×k)); t is the heat transfer time(s); t is a temperature field distribution function;to solve for the intensity (W/m) of the internal heat source in the region 3 ) The method comprises the steps of carrying out a first treatment on the surface of the Where ρ, c, λ are all functions of temperature T.
3. The method for controlling residual stress of multi-point distributed heat source welding for steel bridge deck according to claim 1, wherein in the numerical simulation of temperature field in step2, the following formula is adopted for calculation, if the space domain Ω is discretized into a limited number of unit bodies, the temperature T of a certain unit can be approximated by the node temperature T i Interpolation results, namely:
T＝NT e ；
wherein N is an interpolation function, namely a shape function; t (T) e Is a time-dependent node temperature vector; t is a node temperature vector; k is a heat conduction matrix; c is a heat capacity matrix; p is the temperature load column vector; K. c, P are all temperature dependent variables.
4. The method for controlling welding residual stress of a multipoint distributed heat source for steel bridge deck according to claim 1, wherein the welding stress field simulation in step3 is calculated by adopting the following formula:
dε＝dε e +dε p +dε T
dσ＝Ddε-CdT
wherein dε is the strain increase caused by temperature change; dε e Is an elastic strain increment; dε T Is the strain increment caused by temperature; d is a thermoplastic matrix; c is a vector related to temperature; dε e Is the plastic strain increment;is equivalent strain increment; dε 0 Stress increment caused by temperature change; d (D) e Is an elastic matrix.
5. The method for controlling residual stress of welding of a multipoint distributed heat source for a steel bridge deck according to claim 1, wherein the method for determining the main heating zone and the auxiliary heating zone in step4 is as follows: setting a region at a position 0.8 t-1.2 t away from the U-rib-cover plate joint weld joint as a first main heating region, and setting a region at a position 2 t-4 t away from the U-rib-cover plate joint weld joint as a first auxiliary heating region; setting the area at the position 0.8 t-1.2 t away from the joint weld of the cover plate-U rib-diaphragm plate as a second main heating area and the area at the position 2 t-4 t away from the joint weld of the cover plate-U rib-diaphragm plate as a second auxiliary heating area; wherein t is the thickness of the weld joint parent metal, and temperature measuring points are arranged at the same time.
6. The method for controlling welding residual stress of a multipoint distributed heat source for a steel bridge deck according to claim 5, wherein the welding residual stress of the first main heating zone, the first auxiliary heating zone, the second main heating zone, and the second auxiliary heating zone in step5 can be calculated by the following formula:
Δε＝Δε T +Δε ΔV +Δε trip ；
Δε T ＝α(T)ΔT；
wherein: delta epsilon is the welding residual stress field; delta epsilon T Is a thermoelastic strain; delta epsilon ΔV Is the volume strain; delta epsilon trip Is a phase change plastic strain; f (f) A And f M Respectively austenite volume fraction and martensite volume fraction, T is the current temperature, A C1 For the austenite transformation temperature, A C3 For the austenite transformation end temperature, A and D are the material-related coefficients, M S Is the martensite transformation temperature, C is the material constant, Δf K The volume fraction of the K phase is the volume strain when the phase is completely changed, K is a trip coefficient, S is a bias stress, and ζ is a phase change rate; α (T) is the temperature-dependent linear expansion coefficient, Δt is the temperature variation amplitude, and f' (ζ) is the derivative of the saturation function.
7. The method for controlling residual stress of multi-point distributed heat source welding for steel bridge deck according to claim 5, wherein if the analysis result meets the error requirement within 5%, heating the first and second main heating areas to the heat preservation temperature, heating the corresponding auxiliary heating areas when the main heating areas start to cool down, and cooling the auxiliary heating areas after the main heating areas are cooled down to a certain temperature; if the error requirement within 5% is not met, the temperature of the oxyacetylene flame is adjusted, and the oxyacetylene flame is reapplied until the error requirement within 5% is met.
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