自升式移动平台圆柱型桩腿建造检验要点

桩腿是自升式移动平台的关键结构,一方面需要承受平台主体及甲板货物重力以及受风波影响时产生的弯矩、冲击,还需要承受各种波浪和流载荷;另一方面桩腿自身尺寸及安装精度直接决定平台能否顺利升降。根据以上技术指标以及相关规范、指南的要求,以某多功能海上自升平台建造检验过程为例,阐述该平台桩腿制造检验控制要点,通过焊接工艺选择、制造精度控制,并结合无损检测等措施较好地控制了桩腿的焊接变形、整体尺寸精度,保证其满足各项指标要求,对其他平台桩腿制造提供了工程和理论依据。     

桁架式海洋平台桩腿管节点焊接工艺研究

管节点的焊接是自升式海洋平台桩腿制造中工作量最大的一道工序,它的制造效率和焊接质量直接影响着整个桩腿乃至整个平台的制造进度和使用寿命,文中选择低合金高强钢EQ56为桩腿桁架的材料,对管节点的焊接工艺进行研究,并结合材料特性给出合理的焊接工艺参数。     

海洋平台筒式桩腿结构的焊接变形预测和消除

针对海洋生活平台桩腿的齿条与筒体焊接变形问题,基于迭代子结构法(ISM)和多核并行计算技术的高效热-弹-塑性有限元计算代码,依据结构对称性的特点,建立实际齿条与筒体焊接结构的1/4有限元模型,预测的焊接变形和测量结果趋势一致,数值基本吻合。为了提高建造精度,采用在筒体内表面进行堆焊的工艺措施,产生反变形,抵消齿条与筒体焊接产生的变形,焊接变形量可减70%。     

工艺参数对平板对接焊温度场及残余应力的影响

焊接变形和残余应力对集装箱船的建造质量有着重要影响，通过优化焊接工艺可以有效提高其结构的焊接质量。为选择合理的焊接工艺参数，文章基于ANSYS软件，建立了船舶平板对接焊的有限元分析模型，采用高斯热源模型，对接头的温度场及应力变形进行了数值模拟，并将焊接电流、焊接速度和板厚对平板对接焊残余应力场及变形的影响规律进行了分析和总结，对实际生产中集装箱船结构焊接质量的控制具有一定的参考价值。     

自升式平台桩腿的局部开孔分析

某自升式平台为安装冲桩管线需要在桩腿上开孔,因开孔位置无法避开桩腿高应力区,故需对开孔部位进行局部强度和屈曲分析.本文应用MSC/NASTRAN和ABAQUS有限元分析软件,对单根桩腿建立了详细的有限元模型,除圆柱形桩腿的外壳以外,还包括了内部纵桁、水平撑杆、桩靴细部结构以及开孔周围的加强结构等.边界条件的选取主要是基于平台整体分析得到的结果,考虑到平台主体和桩腿之间的约束变形情况,进行了适当的简化模拟.载荷考虑了自重、静水压力以及作业和自存工况下的风、浪、流载荷.为校核桩腿在整个服役期内是否满足要求,本文所建模型扣除了3mm的腐蚀余量.分析结果表明:桩腿开孔周围结构虽处于较高的应力水平,但仍在许用应力范围之内,并且桩腿的屈曲强度满足要求.     

船体分段钢结构焊接过程仿真

通过有限元与神经网络相结合的方法，模拟了船体上层建筑、舷侧分段钢结构典型部位的焊接过程，并对其温度场、位移场进行了仿真，分析了组焊工序、焊接工艺参数对上述分段钢结构焊接变形的影响。研究结果表明，采用有限元与人工神经网络相结合方法，可以快速分析、预测船舶钢结构的焊接变形，且仿真结果与实焊数值能较好吻合。并分析出影响船体分段钢结构焊接变形的主要因素是钢板拼焊后产生的残余应力，增加消除焊接应力工序，可以明显降低船体分段钢结构焊后产生的变形量。     

NG-2500 X型自升式平台桩腿分段制作

为保证NG-2500X型自升式平台桩腿的尺寸精度和焊接质量,分析了该桩腿的结构形式及主尺寸、母材材质、主舷管及半圆板来料情况,并根据MSC的基本设计要求、美国船级社(ABS) MODU Rules及AWS D1.1等规范制定了一系列装配及焊接措施,涵盖主舷管接长、片体预装及大组装配等。这些措施有效控制了桩腿分段的建造精度和焊接质量,为桩腿合拢打下了坚实的基础,对同类桩腿总体建造精度控制有着重要参考价值。     

面向腐蚀环境的自升式海洋平台桩腿时变可靠性研究

以某公司300ft自升式海洋平台桩腿为研究对象,根据平台桩腿的工作环境的波高和波浪周期对其疲劳环境工况进行划分,采用Airy波理论和PM双参数谱计算平台桩腿不同工况下所受的波浪力谱,通过ANSYS有限元软件对平台进行三维建模,分析其在波浪力下的应力响应。建立桩腿在环境载荷下的可靠性模型,同时针对当前研究中的不足,考虑到腐蚀对于桩腿可靠性的影响,提出并建立在环境载荷与腐蚀耦合作用下的桩腿时变可靠性模型,根据应力响应分析结果,分析桩腿腐蚀最严重区域构件的时变可靠性变化规律,对比两种模型下的桩腿结构可靠性,确定腐蚀因素对桩腿时变可靠性的影响。根据可靠性分析结果,结合自升式海洋平台桩腿的工作环境和服役周期,为平台桩腿的维护与保养提供一定参考。     

“露肋”现象分析与研究

本文分析了影响船舶外形美观的“露肋”现象 ,分析了角焊缝、焊接应力、焊接工艺参数对“露肋”的影响 ,详细介绍了预防和修正“露肋”现象的相应工艺措施。     

自升式钻井平台桩腿建造工艺探索

以海洋石油281/282自升式平台桩腿建造为例,从桩腿的分段划分、建造及焊接作业工艺,合拢及吊装作业步骤等几个方面系统阐述整个桩腿的建造流程,对比国内外桩腿常规建造工艺,所介绍的工艺、工装等具有创新性。     

Influence of the welding sequence on residual stress and distortion of fillet welded structures

T-joints are one of the most common welded joints used in the construction of offshore structures, including ships and platforms. In the present study, a sequentially coupled thermo-mechanical finite element model that considers temperature-dependent material properties, high temperature effects and a moving volumetric heat source was used to investigate the effect of welding sequence on the residual stresses and distortions in T-joint welds. The parameters of Goldak's double ellipsoidal heat source model were predicted using a neural network. The numerical models were successfully validated by the experimental tests. The results show that the welding sequences have significant effects on the residual stresses and distortions, both in the magnitude and distribution mode. The optimization of the welding sequences should be investigated numerically or experimentally before the construction welded structure.     

T形焊接接头残余应力与变形的三维数值模拟

焊接残余应力和变形是个长期困扰船舶行业的难题。本文介绍了预测焊接残余应力和变形的基本数值理论,用MSC.Marc有限元分析软件对T形接头的焊接过程进行了实时三维数值模拟,并对焊接温度场、残余应力分布以及角变形计算结果进行了分析说明。     

Welding-induced residual stresses and distortions of butt-welded corroded and intact plates

The welding-induced residual stresses and distortions of butt-welds between non-corroded and corroded steel plates are studied experimentally and numerically, simulating a repair in an aged structure. Butt welds are made between plates with different corrosion levels and intact ones, and temperature distributions and distortions have been measured. Finite element analyses of the butt-welded corroded and non-corroded plates are performed to estimate the welding-induced distortions and residual stresses for different levels of corrosion degradation. The environmental conditions during the welding repair process are also accounted for. Experimentally evaluated mechanical properties of corroded steel plates as a function of the temperature during the welding process are employed in non-linear finite element analyses. The importance of the material properties as a function of the severity of the steel plates' corrosion degradation on the welding-induced distortions and residual stresses is also quantified. This study shows the importance of considering the ageing of steel in the repair process. The developed methodology allows critical operational decisions to be made with greater ease and confidence in analysing the welding-induced distortions and residual stresses when ageing structures are repaired to extend their service life. Furthermore, different welding sequence scenarios may be analysed to identify the most appropriate repair solution in minimising the repair cost.     

Influence of tacking sequence on residual stress and distortion of single sided fillet submerged arc welded joint

Submerged arc welding (SAW) is advantageous for joining high thickness materials in large structure due to high material deposition rate. The non-uniform heating and cooling generates the thermal stresses and subsequently the residual stresses and distortion. The longitudinal and transverse residual stresses and angular distortion are generally measured in large panel structure of submerged arc welded fillet joints. Hence, the objective of this present work is to quantify the amount of residual stress and distortion in and around the weld joint due to positioning of stiffeners tack. The tacking sequence influences the level of residual stress and proper controlling of tacking sequences is required to minimize the stress. In present study, an elasto-plastic material behavior is considered to develop the thermo mechanical model which predicts the residual stress and angular distortion with varying tacking sequences. The simulated result reveals that the tacking sequence heavily influences the residual stress and deformation pattern of the single sided fillet joint. The finite element based numerical model is calibrated by comparing the experimental data from published literature. Henceforth, the angular distortions are measured from an in-house developed experimental set-up. A fair agreement between the predicted and experimental results indicates the robustness of the developed numerical model. However, the most significant conclusion from present study states that tack weld position should be placed opposite to the fillet weld side to minimize the residual stress.     

定位焊顺序对单面埋弧焊接头残余应力和变形的影响（英文）

Submerged arc welding(SAW) is advantageous for joining high thickness materials in large structure due to high material deposition rate. The non-uniform heating and cooling generates the thermal stresses and subsequently the residual stresses and distortion. The longitudinal and transverse residual stresses and angular distortion are generally measured in large panel structure of submerged arc welded fillet joints. Hence, the objective of this present work is to quantify the amount of residual stress and distortion in and around the weld joint due to positioning of stiffeners tack. The tacking sequence influences the level of residual stress and proper controlling of tacking sequences is required to minimize the stress. In present study, an elasto-plastic material behavior is considered to develop the thermo mechanical model which predicts the residual stress and angular distortion with varying tacking sequences. The simulated result reveals that the tacking sequence heavily influences the residual stress and deformation pattern of the single sided fillet joint. The finite element based numerical model is calibrated by comparing the experimental data from published literature. Henceforth, the angular distortions are measured from an in-house developed experimental set-up. A fair agreement between the predicted and experimental results indicates the robustness of the developed numerical model. However, the most significant conclusion from present study states that tack weld position should be placed opposite to the fillet weld side to minimize the residual stress.     

交变载荷下厚板对接焊残余应力的松弛行为

对于承受交变载荷的焊接构件,焊接残余应力的存在对于结构的疲劳寿命影响巨大。由于焊接残余应力形成机理的复杂性,当交变载荷作用时,焊接残余应力的松弛演变具有不确定性,导致该领域的研究难度相当大。迄今为止,鲜有文献就交变载荷下的厚板焊接残余应力松弛行为进行深入报道。采用低周疲劳试验,利用X射线残余应力测试仪,对试件表面焊接残余应力的松弛演变行为进行追踪研究,通过在试件表面近焊缝区布置网状测点,采集测点的横向及纵向焊接残余应力进行数据拟合,在试验对比修正的基础上,最终建立焊接残余应力的松弛演变模型。结果表明：在交变载荷作用下,焊接残余应力会发生松弛,并且,应力松弛量的大小与交变载荷的特征值大小紧密相关。     

大型核电厚壁结构X射线衍射法残余应力测试

采用X射线衍射法（ XRD）对大型核电厚壁结构堆芯板端面、堆芯板与吊篮筒体环焊缝焊前焊后残余应力进行无损测量。研究堆芯板端面、环焊缝焊前焊后残余应力的分布情况及变化规律。结果表明：堆芯板焊前残余应力主要是机加工应力,且焊接过程对其残余应力影响不大;1＃和2＃堆芯板环焊缝轴向残余应力分布趋势明显,呈现焊缝为压应力,母材为拉应力;测试的环向应力在各区域分布不一致;焊接对远离焊缝区域的应力没有影响,远离焊缝区域呈现较大的加工应力。     

Residual stresses at a longitudinal stiffener — Web frame intersection and their effects on crack growth

Stress coining at geometrical discontinuities may introduce compressive residual stresses which will lower the propagation of surface cracks and thus increase the fatigue life. In a non-linear finite element analysis, the residual stresses after welding of a transverse web-frame to a ship hull plating is first estimated. Stress coining of one corner of a longitudinal cut-out in a transverse web-frame is then simulated in detail. The calculated residual compressive tangential stresses in the corner of the cut-out is seen to lower the propagation of edge cracks. Experiments performed on web-frames taken from a shipyard after manufacturing show indeed that large tensile residual stresses exist in the web-frame after welding. Stress coining is therefore believed to have a beneficial effect on the fatigue life.     

焊接残余应力对疲劳寿命影响的定量研究

在以往的研究中,残余应力对疲劳寿命的影响基本上均局限于定性分析,很少给出定量的研究结果。文章基于双参数统一方法,开展了锥柱结合壳处的残余应力对疲劳寿命的定量计算分析,给出了残余应力对疲劳寿命影响范围,并通过试样疲劳试验进行了验证。通过研究,可以看出残余应力没有改变裂纹的扩展趋势,但明显加快了裂纹扩展的过程,明显降低了耐压结构的疲劳寿命。     

Fatigue life estimation of explosive cladded transition joints with the use of the spectral method for the case of a random sea state

The problem with fatigue lifetime estimation of explosive cladded transition joints under random loading conditions has been described. The paper presents the fatigue test results performed for the random state of tension-compression under a generated spectrum according to the Pierson-Moskowitz model. The obtained spectrum has a non-Gaussian characteristic. The tested material consists out of a transition joint clad with four layers of aluminium alloy A5083, A1050, Titanium Grade 1 and steel Grade D. The material has been tested for the existence of residual stresses after the welding process with the hole drilling method. The welding process has been also simulated with ANSYS and the residual stresses have been generated for the Goldak volumetric distribution. The obtained values of residual stresses comprise to the values of real tests performed for the hole drilling method. The information about the residual stress values have been taken into account in the process of fatigue lifetime estimation in the form of non-zero mean stresses compensation inside the clad. The fatigue life has been calculated with the use of the frequency domain method. The Goodman mean stress compensation model has been used in the process of residual stress compensation. The non-gaussianity has been compensated with the use of the Bracessi formula. The obtained fatigue life assessment results have been compared with stand test results. The calculated results are within the scatter area of 3, but individual scatter values have been calculated for calculated series.