High temperature indentation test to improve constitutive model for welding simulation

The high temperature gradients experienced during fusion welding lead to a local dilatation and metallurgical transformations that generate inhomogeneous plastic deformation, residual stresses and distortions in the welded parts which can affect the service life of the structures. To predict such residual stresses and distortions, finite element analysis is nowadays widely used. This work reports a 3D finite element model for welding simulation. The proposed model is based on semi coupled thermo-mechanical analysis using a double ellipsoidal model of heat source. Firstly, a disk heated in its central zone is investigated. Secondly the validation concerns the simulation of a fully 3D two pass butt weld. The idea in this work concerns the calibration of the heat source parameters with the help of the inverse analysis to improve the heat flow predictions. For the stress analysis, an annealing temperature is introduced to force the material to lose its hardening memory above a given temperature. The predicted residual stresses as well as the predicted distortions are found to be sensitive to the annealing temperature.     

Simulation of tube forming process in mannesmann mill

The finite element method (FEM) is used for simulation of the tube piercing process in Mannesmann mill. The numerical model is described with taking into consideration thermal phenomena in metal during forming. The simulated results visualize dynamic distributions of mean stresses, temperature, velocity and shear stresses, especially inside the workpiece. On the basis of the basic parameters, the phenomenon in the piercing process is analyzed. The model is verified by comparing the values of calculated force parameters of the piercing process and those measured in laboratory conditions.     

寒区隧道冻胀效应测试与分析

为研究寒区隧道冻胀力随时间和空间的分布规律, 基于温度场变化定义了测试冻胀力, 通过衬砌压力和钢架应力间接反映真实冻胀力的变化规律; 提出了冻胀力简化测试方法, 研发了温度场-冻胀力同步测试系统; 以四川省省道215线鸡丑山隧道为例, 布置5个测试断面开展大规模现场测试, 并选取典型断面K117+700 (简称700断面) 和K117+600 (简称600断面) 分析了隧道环境温度、围岩温度、衬砌压力与钢架应力; 以围岩冻结(12~次年2月) 和未冻(7~9月) 时对应的衬砌压力和钢架应力差值为测试冻胀力, 结合温度场分析了隧道周边各测点测试冻胀力; 采用现有冻胀模型计算理论冻胀力, 并与测试冻胀力进行了对比, 研究了寒区隧道冻胀规律。分析结果表明: 隧道环境温度随时间呈季节性正弦函数变化, 受环境温度影响, 围岩温度呈季节性正负温变化, 并出现季节性冻融现象; 当围岩为负温时处于冻结状态, 支护系统受到围岩压力和冻胀力的共同作用, 且温度越低冻胀效应越明显, 各断面测点应力峰值均出现在1月, 700断面衬砌和钢架最大应力分别为149kPa、31MPa; 当围岩为正温时处于未冻结状态, 支护系统仅受到围岩压力作用; 同一断面不同测点的测试冻胀力差值可达5.23MPa, 说明冻胀力除与围岩温度有关外, 还与富水条件和围岩级别有关; 最大冻胀力实测值比理论计算值小1.25MPa, 因此, 寒区隧道支护设计时建议考虑89.17%的冻胀力折减系数。      

钢管混凝土拱桥管内混凝土灌注阶段扣索力计算

钢管混凝土拱桥管内混凝土灌注时,会在某些阶段产生超过混凝土容许值的过程拉应力,需要通过张拉扣索力来调整。提出利用拱脚管内混凝土截面应力影响线来寻找最佳扣索点位置,分别计算管内混凝土灌注阶段和单位扣索力下控制截面的应力。根据混凝土施工过程中的容许应力值,计算出混凝土灌注时所需的扣索张拉值。结合在建中的湖北恩施小河特大桥,介绍详细计算方法     

热力耦合作用下拉林铁路桑珠岭隧道岩爆预测

热力耦合作用是高温高地应力隧道岩爆预测中一个新的问题.在新建拉林铁路桑珠岭隧道开挖过程中,利用现场温度测试数据反演并得到隧道不同埋深时的地温,通过热力耦合数值模拟计算得到隧道开挖过程中的洞周应力变化规律,利用卢森、陶振宇、王元汉、樊建平4种岩爆判据对隧道不同温区、不同洞周应力释放率的岩爆发生烈度和岩爆范围进行预测,最后将预测结果与现场岩爆进行了比较分析.研究结果表明:桑珠岭隧道地温梯度为5.5℃/100 m,隧道埋深越大地温越高;在以自重应力场为主的深埋段,最大压应力集中在拱顶和拱脚部位;在45~85℃地温区间,洞周最大切向应力和最大主应力随应力释放率增大而线性增长,当洞周应力释放率为100%时,其增加量分别为84~96 MPa、93~96 MPa,同时岩爆烈度等级也相应增加;判据预测与现场实测的比对表明,高温热力耦合作用在应力释放过程中加速了岩爆发生,在应力释放率前期,陶振宇判据对中等及以上岩爆的发生更加敏感,而在应力释放中后期王元汉判据与实测结果的相似度更为一致.      

Numerical Analysis of Thermal Distortion and Residual Stresses in H13 Steel Due to Vacuum Gas Quenching

IntroductionVacuumgasquenchinginvolvinghighpressuregasasacoolingmedium,is.anincreasinglypoPularheattreatffienttechniquefor1argesteeldieblocks,forexamPleHl3die.ItisconsideredessefltialtounderstandthentheeofthegasflowandtheinfiuencethishasontemPeratureprofilesandresultaflresidualstresseswithintheheattTeatedcomPonent.SimulatingthisprocessinvolvesthesimulationofgasflowinthefurnaceaswellasthesimulationofthethermalbehaviourofthecomPoneni.However,thereisnosinglecomPatersoftwarepackageavailabletot…     

Computer Predictions and Experimental Verification of Residual Stresses and Distortion in Carburizing-Quenching of Steel

IntroductionInordertoobtainimprovedmechanicalpropertiesandfatiguestrengthofmachinecomponents,stlchasgears,shaftsandsoon,carburizing-quenchingprocessasamethodofstirfacehardeningisoftenusedinindustry.Howevef,carbtirizing-quenchingisusuallyaccompaniedwithcarbonconcentrationandleadtodistortion,residualstressesandhardnessofsteelparts.Theeffectofcarboncontentisspeciallysignificantonphasetransformationbel1aviorThispaPerwillpresentthesimulationresultsoftheresidualstressfieldanddistortionofasteelcylin…     

Computer modeling and validations of steel gear heat treatment processes using commercial software DANTE

The heat treatment process of a gear made of AISI 9310 carburized steel is modeled using the commercial heat treatment simulation software DANTE. Both carburization and quenching processes affect the residual stress distribution and distortion of heat-treated parts, which are important to service quality and fatigue life. DANTE/VCARB is used to design the boost/diffuse schedule of a vacuum carburization process. Oil quenching is modeled following the vacuum carburization process. Thermal gradient and phase transformation are two main sources of distortion and residual stresses in quenched parts. The relation of the carbon distribution, thermal gradient, and phase transformations during quenching is studied through the gear modeling example. Because of geometry, the residual stress distribution after quenching is non-uniform along the gear surface. In general, the root fillet has higher residual compression than either the root or tooth face locations after traditional oil quenching of carburized gears. The predicted residual stresses from the oil quenching model are imported into a single tooth fatigue bending model. The gear stresses under bending load indicate the possible cracking locations during the bending fatigue test. The importance of heat treatment residual stresses during gear design is pointed out, and it is commonly ignored in the gear design and manufacturing industry.     

一种难加工材料的斜角切削过程的数值模拟

参数化建模在仿真切削过程中是行之有效的方法。通过接口设计,系统实现了在Marc中对斜角切削方式的参数化建模。基于金属切削理论和有限元分析原理。借助于有限元方法及材料弹塑性变形理论。针对斜角切削方式,通过建立几何模型、材料模型、刀屑摩擦模型、热控模型和切屑分离准则,采用有限元分析软件Marc,对一种难加工材料的切削过程进行数值模拟,得到在不同切削条件下的切削区应力场、温度场。通过对数值模拟后切削力的结果与实验得到的数据进行比较,验证了所建模型的合理性。     

悬索桥隧道式锚碇侧摩阻力近似解析算法

为了解析计算悬索桥隧道式锚碇的侧摩阻力,基于弹性理论,并考虑锚碇前、后锚端边界条件,建立了锚碇侧摩阻力的计算表达式。首先,根据实际锚碇受力情况建立了锚碇分析模型;其次,在Mindlin解的剪应力一般表达式基础上,引入锚碇前、后锚端剪应力为0的条件以及锚碇的静力平衡条件予以修正,得到锚碇侧摩阻力的解析式;最后,引用模型试验结果验证了解析方法的合理性,并结合工程实例进一步揭示了锚碇侧摩阻力的分布规律. 研究结果表明:锚碇摩阻应力沿轴向呈单峰曲线分布模式,解析计算与三维数值模拟的最大摩阻应力平均误差约为8.5%;当主缆拉力较小（1倍设计缆力）时,锚碇自重可导致较小的侧摩阻力;当主缆拉力较大（3.5倍设计缆力）时,锚碇自重对侧摩阻力影响相对减弱;随着主缆拉力逐渐增大,锚碇侧表面可能出现局部剪切破坏,侧摩阻力将产生重分布.      

Computer Prediction on Stress Distribution During Laser Quenching

IntroductionInprocessofindustry,theproblemscoupIedwiththermaIandfOrceareusuaIIymet.LaserqueIlchinginvolvingphasetransformationisoneofthem.HowtosetupafitmatheInatica1modeltosimulatetl1elaserquenchingprocessandhowtocalculateandanalyzenumericallythestresgdistributionarefolIowedwithinterestbymanyresearchersIl'2'3J.Thoseeffol'tsareimportanttooPtilnizethetechnologyparametersandprovideareliablebasisforimprovingthesyntheticallymechanicspropertiesandtheuseagesofmaterials.Alongwithdevelopmentofcomp…     

考虑隧道围岩蠕变的复合式衬砌受力规律

将锚杆作用力视为体力作用于围岩内, 将初期支护与锚杆锚固范围内的围岩视为围岩加固体, 建立了围岩力学模型, 基于统一强度理论分析了隧道蠕变条件下的围岩应力与变形规律, 推导了复合衬砌应力与变形表达式, 分析了隧道围岩蠕变过程中支护结构受力特点及不同初期支护强度下二次衬砌受力变化规律。分析结果表明: 当初期支护按照“初期支护应与围岩共同受力且能保证施工阶段安全”的原则进行设计时, 在围岩蠕变作用下, 锚杆与喷射混凝土最大受力分别为48、286kPa, 与开挖阶段相比分别增大了57.5%、13.7%, 且超过支护结构最大承载力, 说明在进行初期支护设计时, 仅满足隧道开挖过程中围岩稳定而不考虑蠕变产生的附加应力影响, 可能造成隧道运营过程中初期支护结构破坏, 不利于隧道稳定; 当二次衬砌厚度由300mm增大至500mm时, 二次衬砌最大受力增大了40.5%, 荷载分担比由25.2%增大至36.2%, 而增大初期支护强度后, 二次衬砌受力减小了14.5%, 荷载分担比由25.2%减小至22.3%, 说明二次衬砌荷载随初期支护强度增大而减小, 而随自身强度增大而增大, 应重视初期支护与二次衬砌支护强度的协调配置, 实现围岩压力的合理分配; 在软岩地质条件下, 应保证隧道施工过程中围岩稳定并避免围岩蠕变过程中发生结构破坏, 以实现初期支护与二次衬砌共同承担蠕变引起的附加应力。      

斜拉桥锚箱式索梁锚固区应力及传力途径分析

为给出索力在主要焊缝间分配的定量描述及主要板件的受力特点和产生应力集中的原因，用有限单元法对锚箱式索梁锚固区应力进行了计算分析．研究表明：锚垫板传递总索力的约20％，其主要作用不是承担索力，而是将索力传给2块锚箱腹板；2块锚箱腹板与箱梁腹板的焊缝传递总索力的约80％，且2条焊缝传递的索力相近，剪应力沿焊缝长度方向呈“马鞍形”分布；各主要板件在面内、面外集中力及弯矩作用下有应力集中现象．     

地温梯度孕育的岩体热应力对岩爆预测的影响

为使在高地温环境下通过水压致裂获得的应力更加真实地预测岩爆，提出在岩爆预测过程中应考虑地温梯度孕育的岩体热应力. 结合弹性理论获得了在高地温环境下水压致裂的理论应力解；基于此理论应力解对圆形隧道进行了岩爆预测；应用岩体热应力公式对桑珠岭隧址区的岩爆进行了预测. 研究结果表明:在高地温环境下，恒定压力和水平主应力会增加约一倍的岩体热应力，裂隙重开压力会增加约两倍的岩体热应力，垂直应力不变；如果在高地温环境下直接采用水压致裂测得的应力进行岩爆预测，当水平原位地应力大于竖向原位地应力时，得到的岩爆等级偏高，当水平原位地应力在重力应力和竖向原位地应力之间时，得到的岩爆预测位置与实际不一致，当水平原位地应力小于重力应力时，得到的岩爆等级偏低；桑珠岭隧址区的岩体热应力约为重力应力的61%，若不考虑此热应力进行岩爆预测会导致严重的错误.      

Generalization of Results of Computations and Natural Experiments at Steel Parts Quenching

IntroductionThepaPerpresentsthegenera1izationofresultsofnumericalcomputationsandnaturalexperimentsbasedonthesimilaritytheoryandtheoryofregularthermalconditions.Thenumericalcomputationshasbeenmadeonthebasisofsolvingequationsofnon-stationarythermalconductivityandthermoplaSticity.Thegeneralizationofresultsliesinthefactthatwefoundadimensionlessformulaforthedeterminationofthetimeofreachingthemaximumcompressionstressesonthesurfaceofp8rtstobequenched.ThepatstobequenchedaredividedintothreegrouPs:pla…     

Research on a new type of precision cropping method with variable frequency vibration

Aiming at the cropping operations widely applied in practical industry production, a new method of bar cropping is presented. The rotational speeds of actuating motor of eccentric blocks are controlled by a frequency changer, and the shearing die provides the bar with the controllable force, frequency and amplitude of vibration. By utilizing the stress concentration at the bottom of V shape groove on the bar, the low stress bar cropping is realized. The bar cropping experiments of duralumin alloy and steel show that the shear surface has no radial distortion and deviation angle, the cutting force is lower and the die life is longer compared with the common bar cropping method. According to the special feature of cutting surface obtained by the new method, a new method of measurement is proposed and applied to assess the cutting surfaces obtained by the different control curves of frequency. The results show that the linear decrease control method is the best.     

组合梁斜拉桥索梁锚固区桥面板斜向开裂机理与配筋设计方法

为揭示组合梁斜拉桥在悬拼施工时,索梁锚固区斜向裂缝的开裂机理,从实际受力状态出发,分析了该区域桥面板剪应力和正应力的分布特点,并结合应力莫尔圆理论给出了裂缝成因及其形态特征;基于相关规范及桁架模型,提出了斜向配筋和L形配筋设计的抗裂措施;通过台州湾跨海大桥实例分析,验证了锚固区桥面板的应力分布特点与配筋方法的有效性。研究结果表明:悬拼施工时,锚固区桥面板的面内剪应力主要由拉索索力的竖向分力和水平分力提供,纵、横桥向正应力主要由吊重荷载引起的斜拉桥整体弯矩、拉索索力增加引起的局部负弯矩和局部承压提供;纵桥向正应力的增加是引起索梁锚固区主拉应力变大的主要原因,当主拉应力大于混凝土抗拉强度时,桥面板存在较大的斜向开裂风险;考虑到局部承压的作用,裂缝一般首先出现在索梁锚固点附近的桥面板顶部;当逐渐远离锚固区时,局部负弯矩及局部承压影响减小,桥面板顶板正应力减小,主拉应力减小,裂缝的发展方向与纵桥向夹角逐渐减小,同时,桥面板底板正应力由压应力变成拉应力,主拉应力增大,裂缝产生贯通的可能性增大;基于混凝土板斜向开裂的桁架模型,对索梁锚固区配置L形抗裂钢筋,顶板最大主拉应力降低了1.26 MPa,其中,纵桥向正应力最大可减小0.91 MPa,面内剪应力可减小0.50 MPa,即配置抗裂钢筋能够达到一定的抗弯和抗剪的效果。      

机场水泥道面切缝倒角应力分析

为比较机场刚性道面切缝槽口不同倒角形状对减小应力集中的效果,评估倒角工艺对道面功能性能的影响,运用ANSYS分析软件建立道面板切缝位置有限元模型,在道面接缝节点间分别设梁单元和弹簧单元模拟接缝传荷作用,以Boeing777作为荷载机型,对6种不同倒角形式切缝边缘位置的荷载应力和温度应力进行对比分析,并通过现场试验对道面的平整度和摩擦系数进行测试。分析结果表明:各种切缝形式均能明显改善切缝位置的应力状况,距离切缝愈近位置,改善程度愈明显,不同切缝形式对减小应力集中的程度相差较大,其中半径为6mm的圆弧倒角效果最佳;各种切缝构造对道面平整度和摩擦系数的影响较小,均满足技术要求。     

轮轨热接触耦合效应的有限元分析

针对制动热应力问题,运用有限元直接耦合法,对车轮热接触工况进行了模拟,采用耦合方程同时求解温度场和位移场,研究了纯机械载荷工况和热接触耦合工况下轮轨应力分布与变化规律,分析了车轮及钢轨表层材料和次表层材料的变形、温度与应力之间的关系.分析结果表明:由于热应力的影响,车轮表面以下0～1 mm的表层区域等效应力最大值增大了...     

盾构隧道斜螺栓接头受力性能与火灾下温度分布规律

利用有限元计算软件ABAQUS建立了环向复合管片与环向斜螺栓接头的三维实体模型; 考虑复合管片材料的非线性, 采用弹塑性本构模型, 分析了环向斜螺栓接头在常温下的力学特性; 根据HC升温曲线, 分析了接头模型的传热特性, 研究了复合管片衬砌和环向斜螺栓接头在火灾下的温度分布规律。分析结果表明: 采用高强螺栓能够有效减小接头张开量, 增大接头刚度; 在采用高强螺栓的情况下, 斜螺栓最大轴应力易在初始阶段达到屈服, 屈服后接头弯矩和轴力的增大对斜螺栓的应力影响并不大, 但对斜螺栓变形影响较大, 当接头负弯矩从7 kN·m增加到122 kN·m, 接头轴力从368kN增加到734 kN时, 斜螺栓最大应变增加1.6倍, 当接头正弯矩从53 kN·m增加到182 kN·m, 接头轴力从903kN增加到1 056 kN时, 斜螺栓最大应变增加5.9倍; 常温下接缝附近斜螺栓的轴应力呈现反对称分布, 除接缝外其他部位斜螺栓的轴应力基本相等, 约为400MPa, 接缝处轴应力绝对值最大值可达700 MPa; 火灾情况下手孔处温度上升最快且达到的温度最高, 80 min时即可达到1 000 ℃, 接缝处混凝土在100min后达到稳定温度, 螺母处混凝土在150 min后达到稳定温度, 稳定温度均为1 000 ℃左右。