船用双相不锈钢焊接结构疲劳性能研究

文章对船用双相不锈钢焊接结构的焊缝、影响区和母材在不同应力比下分别进行了疲劳裂纹扩展实验,同时利用有限元分析软件进行了数值模拟,得到了裂纹扩展速率da/dN与应力强度因子ΔK的关系曲线。研究结果表明:船用双相不锈钢焊接结构中焊缝裂纹扩展速率最低,抗疲劳裂纹扩展能力最高;母材疲劳裂纹扩展速率最高,抗疲劳裂纹扩展能力最差;焊缝对应力变化的灵敏度最高,热影响区次之,母材最弱;通过实验与模拟对比分析,表明数值模拟对船用双相不锈钢疲劳裂纹扩展速率定量分析是正确的且方法可行。     

Information models and functions for CIM in shipbuilding

In order to make significant progress in design and manufacturing systems, all industries must consider integration. This paper considers information models and functions for a computer integrated design and manufacturing system in shipbuilding. The authors propose the product model and several alterative functions for designing a ship's structure, and develop a “ship definition system for computer integrated design and manufacturing.” This system is called SODAS (System of Design and Assembly for Shipbuilding). An object-oriented concept is used to develop this system. In order to define a ship's structure, the authors propose the product models of “parts member” and “parts connection,” and the product models of “Room,” “Unit,” and “Module” are introduced to define the compartments, internal structures and intermediate products of a ship. Therefore, all information about a product from the design to the production stage is stored in the product model. As well as the product model, the “design function,” “cutting function,” and “virtual assembling function” are introduced. By using the design function, any type of ship's structure can be designed, and by using the cutting function, the design of a ship's structure can be cut into smaller elements. By using the virtual assembling function, a simulation of the manufacture of a ship's structure can be carried out.     

船体小组立机器人焊接三维扫描识别系统设计

针对船体小组立结构件，基于三维点云数据，利用点云和图像处理算法，完成船体小组立结构件的三维扫描、焊缝识别和焊缝拓扑结构分析。基于片体智能化焊接流水线，构建船体小组立机器人焊接三维扫描识别系统。该系统具备对一般筋板类型结构件与交叉类型结构件的焊前扫描、焊缝识别、机器人焊接路径规划和机器人焊接作业生成等功能，经实际验证，可为片体智能焊接流水线实现船体小组立结构件智能化焊接提供准确的视觉信息与作业信息。     

铜管路件焊缝致密度检验方法研究

铜管路件主要由铜管及三通接头焊接而成,焊接的质量对水冷系统有很大的影响。本文研究了铜管路件焊缝致密度的检验方法,介绍了铜管路件焊接方法、影响焊接质量的各种因素及焊接工艺过程。提出了铜管路件焊缝致密度检验方法,该方法首先对检验样本进行制备,接着通过由光学显微镜与计算机组成的成像系统对样本焊缝位置进行显微图像采集,对采集到的焊缝显微图像在图像软件中进行处理,获取焊缝缺陷的长度,从而计算焊缝位置的致密度。     

我国船舶产业智能制造及其标准化现状与趋势

智能制造是“中国制造2025”的主攻方向,对促进我国船舶产业的发展具有重大意义。智能制造的核心是建立互联互通的网络化工业生态,需要标准体系作为支撑。本文讨论智能制造相关技术和标准化趋势,认为现阶段船舶产业制造端宜在巩固夯实已有的数字化和自动化基础上,在互联互通和信息融合层面上进行重点突破。智能制造标准体系与现有的船舶工业标准体系在技术领域上有交集,但关注角度不同。在船舶产业智能制造标准化过程中,应对2个标准体系进行同步更新和维护,形成互补。     

The effect of weld residual stress on fracture toughness at the intersection of two welding lines of offshore tubular structure

Due to the spatial complexity and fabrication characteristics of offshore platforms, it is inevitable to encounter overlaps or proximity of weld lines in tubular joints. Several international standards such as American Petroleum Institute (API), American Welding Society (AWS), and American Institute of Steel Construction (AISC) regulate the minimum distance between primary weld beads; however, any logical and detailed background of this limitation has not been presented. For a non-compliant weld joint where the regulation is not met, fracture toughness calculation is a typical index to verify the structural integrity.This research consists of two parts. First, weld residual stress distributions are calculated by a 3D thermo-mechanical nonlinear Finite Element Analysis. Two crossing welds, a T-weld crossing on a butt weld, are simulated in one model. A separate tee and a butt welding simulations are also performed for a comparative purpose. Second, SIFs and J-integral values are calculated at the surface and deepest crack tip locations for four different types of semi-elliptical surface cracks. Four cracks are embedded into the weld model and the residual stress distribution from the 3D thermo-mechanical FEA are mapped to a 3D FE crack model as initial conditions. An additional axial tensile load is also imposed. SIF values are compared with those using the weighting function method for the butt weld model subject to three load cases, i.e., tensile stress only, weld residual stress only, and both of them. From the simulation, a tubular joint containing a chord girth weld intersected with weld beads of brace is found to show lower the SIF values than that having only a girth weld on chord.     

Development of a mobile welding robot for double-hull structures in shipbuilding

This paper describes the development of a self-driving mobile welding robot. The robot is used to weld U-shaped welding areas in enclosed double-hull structures. In order to place itself inside the double-hull structure, the robot is capable of passing through an access hole 600 mm wide and 800 mm high. This research addresses the mechanical and control systems of the robot. The mechanical system of the robot consists of an eight-axis mobile platform, and a six-axis welding unit. The control system consists of a main controller, a welding machine controller (arc sensor board), and seam tracking sensors, i.e., a touch sensor, a laser sensor, and an arc sensor. To reduce the number of cables that would be dragged by the welding robot, the main controller is designed as an embedded type that is mounted on the back of the mobile platform.     

药芯焊丝焊缝夹杂物探讨

药芯焊丝陶质衬垫ＣＯ２半自动单面焊焊缝中的夹杂物偏多。通过对焊缝中夹杂物的微观金相分析,计算机图像分析系统定量分析,扫描电镜形貌分析,Ｘ射线能谱微区成分分析及俄歇电子能谱微区成分分析,证实该类夹杂物主要是球状氧化物。球状氧化物是由于药芯焊丝在强氧化性气氛中焊接冶金过程脱氧不完全产生的,并从药芯焊丝焊接冶金的特点,探讨了由于夹杂物增多导致产生焊接缺陷的原因及防止措施。     

激光焊接技术在舰船建造中的应用

介绍了激光焊接技术的发展历史、工业焊接用激光源的基本特点、激光焊接技术用于造船业的优势及其存在的困难,重点介绍了激光焊接技术在舰船建造中的应用实例,包括激光焊接大型船板、激光焊接型材、焊接瓦棱夹层板、激光焊接修复等,指出了在舰船建造中开展激光焊接技术研究的必要性。     

Adaptive approximation in multi-objective optimization for full stochastic fatigue design problem

As the size of ship has grown rapidly, the importance of exact fatigue strength assessment has been recognized more and more. High concern about fatigue crack often raises target fatigue life to two or three times of ship lifetime. This leads to the use of very thick plates to reduce dynamic stress range or the application of weld toe grinding to reduce stress concentration or removing weld defects. However, such measures can cause some troubles in fabrication process. As a fatigue strength assessment procedure, full stochastic fatigue analysis based on wave loads analysis has been recommended due to its high accuracy and straightforward approach. However, its huge computing time hinders a ship designer from making iterative explorations for a better design to minimize the use of aforementioned measures.This paper proposes an efficient approach to optimize plate thicknesses around hot spots and the applications of weld toe grinding with meeting the required target fatigue life based on the full stochastic fatigue assessment. Two conflicting objectives are taken into consideration; to minimize steel weight and to minimize total weld toe grinding length. Whether to employ weld toe grinding or not for a hot spot can be seen as a selection variable. In order to treat such selection variables along with continuous variables in the multi-objective optimization, Multi-objective Genetic Algorithm (MOGA) is introduced. This paper also employs adaptive approximation framework to resolve the computational burden of the full stochastic fatigue analysis in the optimization. The strategy to refit approximations iteratively can minimize the required number of analysis. A convergence criterion of the adaptive approximation framework is newly proposed considering the feature of discrete objective function attributed to the introduction of selection variables. One of the objective functions, toe grinding length, is purely depending on how many hot spots toe grindings are applied to. The proposed approach is applied to a liquid dome opening problem of LNG carrier, which is known as one of the most difficult parts to satisfy required fatigue strength due to the stress concentration caused by its large opening and weld attachments on upper deck.     

基于区块链的海上风电机组备件生命周期管理平台

海上风电机组（Wind Turbine Generator System,WTGS）备件的相关数据通常存储在中心化的数据库中,很难在合作方之间共享,数据安全性难以得到保证。提出一种基于区块链的海上WTGS备件生命周期管理平台,以促进备件生命周期中的数据交换和信息共享。备件服务中的即时追溯服务、障碍评估服务、主动维护服务和远程监控服务有助于管理者和决策者对备件进行管理和决策。研究结果为备件生命周期管理及区块链技术实际应用提供一定的理论和实践参考。     

船体零件智能优化排样系统的设计研究

针对船体零件的排样问题,开发了基于智能算法的板材套料优化排样系统。该系统采用粒子群算法,并将免疫记忆和浓度机制引入算法提高了零件的排序优化速度。通过零件图形信息数据库管理模块和排样解码算法,实现图形的输入和编码、定位排放和正交靠接及自动计算生成最优排样结果。排样实例表明了该系统具有良好界面和人机交互功能,且有效提高了排样自动化程度和材料利用率。     

Development of a finite element modeling system for ship structures

In ship structural design, many structural analyses by the finite element method are carried out on models at several different scale levels; for example, a whole ship, cargo hold parts, and detailed structures. However, one serious problem with this design and analysis process is that the generation of the finite element models for a complex configuration is very difficult and laborious. To overcome this problem, an object oriented, finite element modeling system, MODIFY, has been developed by the authors. In this paper, the concept of the finite element modeling system and the techniques for the construction of the system are explained. First, the object oriented data structure of the system, based on the Part-Object concept, is proposed. In this concept, not only the geometry of the domain but also the analytical conditions, such as boundary conditions and material properties, and the finite element model, are represented by the object oriented data structure. By using this data structure, effective finite element model generation can be expected. Second, a mesh generation algorithm based on the frontal method is described. The original frontal method by S.H. Lo was improved for application to three-dimensional curved surfaces. A new inner node placement technique to make quadrilateral elements around stress concentrated areas is also proposed. These techniques are suitable for ship structures, and more accurate results from the finite element analysis can be expected. Moreover, the parallel mesh generation is implemented in MODIFY by using the client-server concept to accelerate mesh generation. Third, a prototype system for the automatic finite element model generation for different analysis levels is proposed. The system is based on the concept of the PD part, which is the part in the design and production stage, and automatic computing of the intersection between PD parts. The validity of this system is demonstrated by some examples.     

岸边集装箱桥式起重机撑管封板疲劳开裂分析

为探究岸边集装箱桥式起重机撑管封板受载情况和焊缝危险位置的疲劳寿命,对65 t/60 m岸边集装箱桥式起重机的典型载荷工况进行分析。计算门框上水平撑管的疲劳载荷幅值,研究撑管封板焊缝的受载情况,应用S-N曲线法计算焊缝的结构应力并分析焊缝危险位置的疲劳寿命。结果表明,最大von Mises应力出现在封板与节点板端部角焊缝的焊趾上。封板焊缝危险部位的疲劳寿命无法满足岸边集装箱桥式起重机安全服役30 a的要求。     

新型自行走电动船用客梯的设计

为满足旅客上、下船安全、舒适的要求,设计了新型自行走电动船用客梯。介绍主要部件的设计方案,整车的技术参数和液压系统工作原理。新客梯投入使用后,受到旅客好评,提升了服务质量和港口形象。     

舰船除锈喷漆机器人的研究与设计

为了改进舰船修造行业除锈、喷漆工作落后的、传统的人工作业方式,设计了一种具有除锈、喷漆功能的机器人装置。该机器人采用直角坐标和柱坐标相结合的设计方法,通过主从遥控控制或自动轨迹规划控制,能够实现平面和曲面作业。详细介绍了该机器人的本体结构、驱动方式和控制系统构成,并对机器人自动工作方式的轨迹规划作了阐述。实践表明,使用该机器人代替人工作业,不仅可以减轻操作工人的劳动强度,还可提高工作效率和施工质量,具有较强的应用价值。     

Prediction of residual stresses induced by low transformation temperature weld wires and its validation using the contour method

Welding residual stresses are one of the main factors influencing the engineering properties of welded structures, and should be taken into account during designing and manufacturing products such as ships, bridges, etc. Recently, both computational and experimental methods play a significant role for providing residual stresses. The contour method (CM) became one of the most powerful techniques that can provide measurement of residual stresses normal to a plane of interest. In this method a component is cut at any plane of interest. Displacements normal to the cut surface are measured and then processed. Using the Thermal–Elastic–Plastic Finite Element Method (TEP-FEM), residual stresses after welding can be predicted. As well as, the elastic FEM can be used to reproduce residual stresses from measured longitudinal displacements in the CM.The main objective of this paper is to evaluate the effectiveness of different low transformation temperature (LTT) weld wires using TEP-FEM and the CM. In the simulation part, a computational approach is developed to numerically simulate both of welding and the CM. In the TEP-FEM, phase transformation is considered for LTT welds, additionally volume change and variation of mechanical properties with temperature are considered. In the simulated CM, welded specimens to be measured are replaced by TEP-FE models. Then the procedure of the CM is examined before applying it to real measurements. The simulated CM successfully predicted how the CM would reconstruct the residual stresses if applied experimentally. In the experimental part, welding is conducted using conventional and various LTT weld wires. Longitudinal residual stresses produced due to welding are measured using the CM. The results of TEP-FE simulation and the CM show the effectiveness of the different LTT weld wires in introducing compressive stresses in the weld. It is also observed that the applied LTT weld wires, which have almost the same martensitic transformation start temperatures, do not show big difference in the induced compressive residual stresses in the weld metal.     

Targeting market opportunity for port growth: a CART-based decision support system

Complex decisions, such as those facing port managers when targeting market opportunities for growth, are multifaceted and follow complex patterns of sequential and iterative decision subsets that are not well captured nor represented by current parametric modelling approaches. Nonetheless, understanding how such decisions are made and the patterns they follow have important implications for policy formulation and execution. This paper uses a classification and regression trees (CART) framework—a non-parametric decision trees modelling approach-and develops a decision support system to assist port managers in making effective decisions about market opportunities they should pursue for growth. The CART-based decision support system reveals the predictive structure and complex patterns that the market opportunity selection process follows. It also advances our knowledge and understanding of the interaction and behaviour of the key decision variables and the decision makers in a port context.     

基于定位信息的天线伺服系统的设计与实现

为解决对海微波通信系统中岸站定向天线无法实时对准海上移动站的问题,研制了基于定位信息的天线伺服系统。系统采用基于AD2S83AP的轴角转换电路实现对天线转向的精确控制,稳定度高,通用性好,具备较大的工程实用价值,该文详细介绍了系统的结构、功能及各部分的具体实现。     

A simplified non-linear numerical method for the assessment of welding induced deformations

Welding numerical simulation has always been a formidable challenge because of the involved complex phenomena to be modelled. The task is increasingly challenging when multi-runs welding or welding of ships is needed to be modelled. In these cases, the computational effort is so high that solving the problem via computational welding mechanics is impossible so far. Alternatively, different simplified numerical strategies were developed to overcome this issue such as those based on the inherent strain. Unfortunately, such numerical models are rarely able to capture the effects induced by a variation of the welding sequence or clamping conditions since they are solved in the elastic filed; most of them are therefore not useful to the design optimization of a welded assembly. In this scenario, a new approach is proposed to quantify the welding induced deformations that uses virtual elements to model the weld bead in the elastic-plastic filed and auxiliary elements to apply equivalent loads determined by experiments on a single welded joint. A specific inverse analysis algorithm has been developed to use the method. The model was applied to a real welded assembly in which both the welding sequence and clamping condition were varied. In addition, for the numerical validation, a novel registration algorithm has been developed to move from solid geometries to middle plane representations. Numerical results were found in good agreement with those obtained by experiments even when the welding sequence and clamping conditions are changed.