CN110133016A - A Method of Welding Numerical Simulation Assisted X-ray Diffraction Detection of Residual Stress - Google Patents
A Method of Welding Numerical Simulation Assisted X-ray Diffraction Detection of Residual Stress Download PDFInfo
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Abstract
本发明提供一种焊接数值模拟辅助X射线衍射检测残余应力的方法，包括如下步骤：建立焊接结构件的三维模型并对其进行仿真分析，得到焊接结构件残余应力的集中区域以及集中区域残余应力的平均值；在焊接结构件的残余应力集中区域内选取至少两个检测点，并采用X射线衍射法检测各检测点的残余应力；判断各检测点的残余应力与集中区域残余应力平均值之差是否大于第二设定值，如果不大于，则检测结果正确。本发明所提供的技术方案，根据检测到的各检测点残余应力与集中区域的残余应力平均值之差判断出测试的结果是否存在错误，从而提高对焊接结构件残余应力检测结果的准确性。
The invention provides a method for detecting residual stress assisted by welding numerical simulation by X-ray diffraction, which includes the following steps: establishing a three-dimensional model of a welded structural part and performing a simulation analysis on it to obtain the concentrated area of the residual stress of the welded structural part and the residual stress in the concentrated area The average value; select at least two detection points in the residual stress concentration area of the welded structural parts, and use the X-ray diffraction method to detect the residual stress of each detection point; judge the residual stress of each detection point and the average value of the residual stress in the concentrated area Whether the difference is greater than the second set value, if not, the detection result is correct. The technical solution provided by the present invention judges whether there is an error in the test result according to the difference between the detected residual stress of each detection point and the average value of the residual stress in the concentrated area, thereby improving the accuracy of the residual stress detection result of the welded structural parts.
Description
技术领域technical field
本发明属于焊接结构件检测技术领域，具体涉及一种焊接数值模拟辅助X射线衍射检测残余应力的方法。The invention belongs to the technical field of detection of welded structural parts, and in particular relates to a method for detecting residual stress assisted by welding numerical simulation by X-ray diffraction.
背景技术Background technique
各种机械构件在制造过程中会产生残余应力，适当的残余应力可能成为零件强化的因素，不适当的残余应力则可能导致变形和开裂等工艺缺陷；在机械产品完成之后，残余应力将影响构件的静载强度、疲劳强度、耐应力腐蚀能力及形状尺寸的稳定性。一个构件残余应力状态如何，是设计者、制造者和使用者共同关心的问题。Various mechanical components will produce residual stress during the manufacturing process. Appropriate residual stress may become a strengthening factor for parts, while inappropriate residual stress may cause process defects such as deformation and cracking; after the mechanical product is completed, the residual stress will affect the components. Excellent static load strength, fatigue strength, stress corrosion resistance and shape and size stability. What is the residual stress state of a component is a common concern of designers, manufacturers and users.
残余应力的检测方法有盲孔法、轮廓法、X射线衍射法、中子衍射法，且主要分为有损检测和无损检测两大类，在各种无损检测残余应力的方法中，X射线衍射法作为无损检测应力的最佳手段，是目前公认最可靠和最实用的检测技术，在国内外广泛应用于机械工程和材料科学。The detection methods of residual stress include blind hole method, contour method, X-ray diffraction method, and neutron diffraction method, and are mainly divided into two categories: destructive testing and nondestructive testing. Among various nondestructive testing methods for residual stress, X-ray Diffraction method, as the best method for non-destructive testing of stress, is currently recognized as the most reliable and practical testing technology, and is widely used in mechanical engineering and material science at home and abroad.
但是在采用X射线衍射法对焊接结构件进行检测时，需要调节测试设备与内侧焊接结构件之间的距离等操作，过程比较麻烦；当对比较大型的设备，如GIS设备进行检测时，测试过程更为复杂，需要花费大量的时间。而且在测试过程中，一旦测试设备与焊接结构件之间设置的位置存在偏差，就会影响对焊接结构件残余应力测试的准确性。However, when using the X-ray diffraction method to detect welded structural parts, it is necessary to adjust the distance between the test equipment and the inner welded structural parts, and the process is cumbersome; when testing relatively large equipment, such as GIS equipment, the test The process is more complicated and takes a lot of time. Moreover, in the testing process, once there is a deviation in the position set between the testing equipment and the welded structural part, it will affect the accuracy of the residual stress test of the welded structural part.
发明内容Contents of the invention
本发明的目的在于提供一种焊接数值模拟辅助X射线衍射检测残余应力的方法，用于解决现有技术中在采用X射线衍射法对焊接结构进行残余应力检测时，由于测试设备与焊接结构之间设置位置存在偏差而造成检测结果准确性较差的问题。The purpose of the present invention is to provide a method for welding numerical simulation assisted X-ray diffraction detection of residual stress, which is used to solve the problem of the gap between the testing equipment and the welding structure when the X-ray diffraction method is used to detect the residual stress of the welding structure in the prior art. There is a deviation in the setting position between them, which causes the problem that the accuracy of the detection result is poor.
为实现上述目的，本发明提供的技术方案是：To achieve the above object, the technical solution provided by the invention is:
一种焊接数值模拟辅助X射线衍射检测残余应力的方法，包括如下步骤：A method for welding numerical simulation assisted X-ray diffraction detection of residual stress, comprising the following steps:
(1)建立焊接结构件的三维模型并对其进行仿真分析，得到焊接结构件残余应力的集中区域以及集中区域残余应力的平均值；(1) Establish a three-dimensional model of the welded structural part and perform simulation analysis on it to obtain the concentrated area of the residual stress of the welded structural part and the average value of the residual stress in the concentrated area;
(2)在焊接结构件的残余应力集中区域内选取至少两个检测点，并采用X射线衍射法检测各检测点的残余应力；(2) Select at least two detection points in the residual stress concentration area of the welded structural parts, and use the X-ray diffraction method to detect the residual stress of each detection point;
判断各检测点的残余应力与集中区域残余应力平均值之差是否大于第二设定值，如果不大于，则检测结果正确。It is judged whether the difference between the residual stress at each detection point and the average value of residual stress in the concentrated area is greater than the second set value, and if not, the detection result is correct.
本发明所提供的技术方案，首先根据焊接结构件的三维模型确定其残余应力集中区域，在采用X射线衍射法进行测试过程中，根据检测到的各检测点残余应力与集中区域的残余应力平均值之差，判断出测试的结果是否存在错误，从而提高对焊接结构件残余应力检测结果的准确性。In the technical solution provided by the present invention, firstly, the residual stress concentration area is determined according to the three-dimensional model of the welded structural part, and in the process of testing by X-ray diffraction method, the average residual stress of each detection point and the residual stress of the concentrated area The difference between the values can be used to judge whether there is an error in the test results, thereby improving the accuracy of the residual stress detection results of the welded structural parts.
作为对检测点残余应力检测结果是否存在错误的进一步改进，如果各检测点的残余应力与集中区域残余应力的平均值之差大于第二设定值，则判断各检测点的残余应力之差是否大于第三设定值；如果其中两个检测点的残余应力之差大于第三设定值则检测结果正确，否则检测结果错误。根据检测点残余应力之差对检测结果进一步进行验证，能够提高对检测结果准确性判断的可靠性。As a further improvement on whether there is an error in the detection result of the residual stress at the detection point, if the difference between the residual stress at each detection point and the average value of the residual stress in the concentrated area is greater than the second set value, then it is judged whether the difference between the residual stress at each detection point is greater than the third set value; if the difference between the residual stresses of the two test points is greater than the third set value, the test result is correct, otherwise the test result is wrong. The detection results are further verified according to the residual stress difference of the detection points, which can improve the reliability of the accuracy judgment of the detection results.
作为对焊接结构件三维模型仿真的进一步改进，利用焊接数值模拟软件对所述焊接结构件的三维模型进行仿真分析。利用焊接数值模拟软件进行仿真分析，能够减少测试的成本，提高仿真的效率。As a further improvement to the simulation of the three-dimensional model of the welded structural part, the simulation analysis of the three-dimensional model of the welded structural part is carried out by using welding numerical simulation software. Using welding numerical simulation software for simulation analysis can reduce the cost of testing and improve the efficiency of simulation.
作为对焊接结构件的进一步限定，所述焊接结构件为GIS壳体。将焊接结构件设为GIS设备，能够对GIS设备的残余应力进行检测。As a further definition of the welded structural part, the welded structural part is a GIS shell. Setting the welded structural parts as GIS equipment can detect the residual stress of the GIS equipment.
作为对残余应力集中区域的进一步改进，所述残余应力集中区域是指残余应力值大于最大应力值0.75倍的区域。根据残余应力的最大值确定残余应力集中区域，更符合仿真测试的需求。As a further improvement on the residual stress concentration region, the residual stress concentration region refers to a region where the residual stress value is greater than 0.75 times the maximum stress value. The residual stress concentration area is determined according to the maximum value of the residual stress, which is more in line with the requirements of the simulation test.
附图说明Description of drawings
图1为本发明实施例中焊接数值模拟辅助X射线衍射检测残余应力的方法的流程图；Fig. 1 is a flowchart of a method for detecting residual stress assisted by welding numerical simulation by X-ray diffraction in an embodiment of the present invention;
图2为本发明实施例中对焊接结构件三维模型仿真计算得到的残余应力分布图；Fig. 2 is the residual stress distribution diagram obtained by the simulation calculation of the three-dimensional model of the welded structural part in the embodiment of the present invention;
图3为本发明实施例中焊接结构件残余应力集中区域的示意图。Fig. 3 is a schematic diagram of a residual stress concentration area of a welded structural member in an embodiment of the present invention.
具体实施方式Detailed ways
本发明的目的在于提供一种焊接数值模拟辅助X射线衍射检测残余应力的方法，用于解决现有技术中对焊接结构件残余应力检测结果准确性较差的问题。The object of the present invention is to provide a method for detecting residual stress assisted by welding numerical simulation by X-ray diffraction, which is used to solve the problem of poor accuracy of residual stress detection results of welded structural parts in the prior art.
为实现上述目的，本发明提供的技术方案是：To achieve the above object, the technical solution provided by the invention is:
一种焊接数值模拟辅助X射线衍射检测残余应力的方法，包括如下步骤：A method for welding numerical simulation assisted X-ray diffraction detection of residual stress, comprising the following steps:
(1)建立焊接结构件的三维模型并对其进行仿真分析，得到焊接结构件残余应力的集中区域以及集中区域残余应力的平均值；(1) Establish a three-dimensional model of the welded structural part and perform simulation analysis on it to obtain the concentrated area of the residual stress of the welded structural part and the average value of the residual stress in the concentrated area;
(2)在焊接结构件的残余应力集中区域内选取至少两个检测点，并采用X射线衍射法检测各检测点的残余应力；(2) Select at least two detection points in the residual stress concentration area of the welded structural parts, and use the X-ray diffraction method to detect the residual stress of each detection point;
判断各检测点的残余应力与集中区域残余应力平均值之差是否大于第二设定值，如果不大于，则检测结果正确。It is judged whether the difference between the residual stress at each detection point and the average value of residual stress in the concentrated area is greater than the second set value, and if not, the detection result is correct.
下面结合具体实施方式对本发明的技术方案作进一步说明。The technical solution of the present invention will be further described below in conjunction with specific embodiments.
本实施例提供一种焊接数值模拟辅助X射线衍射检测残余应力的方法，用于解决现有技术中在对焊接结构件的残余应力进行检测时检测结果准确性较差的问题。This embodiment provides a method for detecting residual stress by welding numerical simulation assisted by X-ray diffraction, which is used to solve the problem of poor accuracy of detection results in the prior art when detecting residual stress of welded structural parts.
本实施例所提供的焊接数值模拟辅助X射线衍射检测残余应力的方法，其具体流程如图1所示，包括如下步骤：The method of welding numerical simulation assisted X-ray diffraction detection residual stress provided in this embodiment, its specific process is shown in Figure 1, including the following steps:
(1)建立焊接结构件的三维模型；(1) Establish a three-dimensional model of the welded structural parts;
本实施例中建立的三维模型是焊接结构件的有限元模型；The three-dimensional model established in this embodiment is a finite element model of a welded structure;
(2)利用焊接数值模拟软件对焊接结构件的有三维模型进行仿真分析，根据仿真的结果观察残余应力的分布图，将其中残余应力大于最大应力值75％以上的区域作为残余应力的集中区域；(2) Use the welding numerical simulation software to simulate and analyze the three-dimensional model of the welded structural parts, observe the distribution diagram of the residual stress according to the simulation results, and use the area where the residual stress is greater than 75% of the maximum stress value as the concentration area of the residual stress ;
如通过对焊接结构件的三维模型进行仿真分析，得到焊接结构件的残余应力分布如图2所示,焊缝两侧一般为应力集中的区域，通过分析残余应力分布图，获得残余应力较大的区域，依据此图在实际焊件划定检测范围，作为后期质量检测重点对象；在取焊接结构件上选取残余应力的集中区域，如图3所示，根据仿真结果，在已划定的应力集中区域，利用X射线衍射仪检测应力值，并与仿真结果进行对比；For example, through the simulation analysis of the three-dimensional model of the welded structural parts, the residual stress distribution of the welded structural parts is shown in Figure 2. The two sides of the weld are generally stress-concentrated areas. By analyzing the residual stress distribution diagram, it is obtained that the residual stress is relatively large. According to this figure, delineate the detection range in the actual weldment as the key object of later quality inspection; select the concentrated area of residual stress on the welded structural parts, as shown in Figure 3, according to the simulation results, in the delineated In the stress concentration area, the stress value is detected by X-ray diffractometer and compared with the simulation result;
分析图2中残余应力分布，结果显示在焊缝周围残余应力值较大，因此在样件检测时重点检测焊缝周围的残余应力；图3中标记的检测区域为残余应力较为集中的范围，在检测时重点关注该区域残余应力；Analyzing the residual stress distribution in Figure 2, the results show that the residual stress value around the weld is relatively large, so the residual stress around the weld is mainly detected during the sample inspection; the detection area marked in Figure 3 is the area where the residual stress is relatively concentrated. Focus on the residual stress in this area when testing;
(3)计算焊接结构件残余应力集中区域残余应力的平均值，设该平均值为n0；(3) Calculate the average value of the residual stress in the residual stress concentration area of the welded structural parts, and set the average value to n0;
残余应力均值是在残余应力集中区域选取10-30个节点，去除最大值和最小值，然后求平均值；The average value of residual stress is to select 10-30 nodes in the residual stress concentration area, remove the maximum and minimum values, and then calculate the average value;
(4)在焊接结构件残余应力集中区域内选取两个检测点，采用X射线衍射法对这两个检测点的残余应力进行检测，得到这两个检测点的残余应力分别为n1和n2；(4) Select two detection points in the residual stress concentration area of the welded structure, and use the X-ray diffraction method to detect the residual stress of these two detection points, and obtain the residual stresses of these two detection points as n1 and n2 respectively;
(5)判断焊接结构件残余应力集中区域残余应力的平均值n0与两个检测点的残余应力n1和n2之间的差值是否大于第二设定值；即判断n0与n1之间的差值是否大于第二设定值，以及n0与n2之间的差值是否大于第二设定值；(5) Judging whether the difference between the average value n0 of the residual stress in the residual stress concentration area of the welded structural part and the residual stresses n1 and n2 of the two detection points is greater than the second set value; that is, to judge the difference between n0 and n1 Whether the value is greater than the second set value, and whether the difference between n0 and n2 is greater than the second set value;
如果n0与n1之间的差值不大于第二设定值，且n0与n2之间的差值不大于第二设定值，则判断为检测结果正确，接收检测结果；If the difference between n0 and n1 is not greater than the second set value, and the difference between n0 and n2 is not greater than the second set value, it is judged that the detection result is correct, and the detection result is received;
否则判断n1与n2之间的差值是否大于第三设定值；Otherwise, judge whether the difference between n1 and n2 is greater than the third set value;
如果不大于，则检测结果正确，接收检测结果；If not greater than, the detection result is correct and the detection result is received;
否则检测结果出现错误，不接收检测结果。Otherwise, an error occurs in the test result, and the test result is not accepted.
本实施例中所检测的焊接结构件，是GIS设备的壳体。The welded structural part detected in this embodiment is the casing of the GIS equipment.
本实施例中的第二设定值为100Mpa，第三设定值为50Mpa；作为其他实施方式，可第二设定值和第三设定值可根据需求设置。In this embodiment, the second set value is 100Mpa, and the third set value is 50Mpa; as other implementation manners, the second set value and the third set value can be set according to requirements.
本实施例中在焊接结构件的应力集中区域内选取了两个检测点；作为其他实施方式，检测点的数量可根据需求设置。In this embodiment, two detection points are selected in the stress concentration area of the welded structure; as other implementation manners, the number of detection points can be set according to requirements.
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
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